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General => General discussion => Non-Golf gallery => Topic started by: MrBounce on 19 June 2011, 15:55
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It's a 1981 Mk 1 Mini Midas Coupe which has been standing a while. Fibreglass body, so no rust (which is great coz I can't weld), has an engine in bits, everything needs reconditioning and the interior is horrific. It has the nastiest pair of seats I have ever seen...
It's a bit of a challenge but it's something I've been wanting to do for a while. I know Minis well, so the mechanicals shouldn't cause too much of an issue. I reckon I'll be learning lots about fibreglass though!! :grin: :grin: :grin:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas1.jpg)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas13.jpg)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas16.jpg)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas14.jpg)
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looks fun, the fibreglass can still rot if moisture has got in (ask early VX220 owners :lipsrsealed:) but at least it's easier to repair :laugh:
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Looks like a fun little project!
You'll probably be spending time on electrics as well as fibreglass! Most kitcars have horrible wiring looms :sick: But it will all be basic!
Happy to help if i can with fibreglass questions?
Cheers
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Love it!
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Sweet :cool: :cool: :cool: :cool: :cool:
I heard "Mr bounce picking up a project" on radio two on Friday :grin:
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just think with a bit of time and effort you could turn it into this :rolleyes:
(http://i1221.photobucket.com/albums/dd478/gimp6969/DSC00164.jpg)
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Nightmare electrics with no metal body, expect 3 times the amount of wiring as a normal metal bodied car
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looks nice, what you gonna do to it, restore it to original condition? or as neer as you can get?
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Different :cool:
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Cool don't see many of them about even at shows.
I love the wheels on the clubby estate dunlop D1 classic wheel and totally different to minilites. I have a set of 10" D1 for my 69 MKII which I need to get refurbed
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Yes i've bumped this Mr Bounce! I found the thread on another forum that you posted in the Hobbies thread. After reading all of it i thought it would be unfair not to keep us lovely folk here not up to date!!!
Awesome work so far! :afro:
How or why you haven't just given up i do not know! :grin:
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:cool:
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Oops I haven't updated this for absolutely ages on this site so this may take a while... Will copy and paste from the other forums I'm on so the dates will be a bit out.
Well I've managed to get out into the garage for an evening; my first job was to strip the spare engine that came with the Midas. It is believed to be an 1100 (no engine number), which apparently smoked and might have needed a rebuild. The main thing is, this engine is in the way and needs to be gone. My friend Shaun wants the gearbox casing, so I will cannibalise the engine for what I want (Non-verto clutch & flywheel bits), Shaun gets the whole gearbox and the rest will go up on Ebay at 99p start (buyer collects!). :grin:
I began by draining the oil. My mate Matt and I manhandled the lump onto some handy concrete blocks I have (easy as we're both built like rugby prop-forwards :) ) and after some persuasion with a 3ft bar and socket the sump plug was removed. What came out was not pretty and was darker and thicker than a molasses vat at night. :shock: My guess is it didn't taste as good.
http://s511.photobucket.com/albums/s353/MrBounce38/Midas/?action=view¤t=Midas017.jpg
Time to remove the flywheel. Off came the cover and it was clear that this would have been undriveable as the oil seal had failed big time - so much oil spray in the cover and also on the pressure plate and backplate. Amazingly the flywheel gave up without too much of a fight - there was an extremely satisfying "crack!" - and then I set about removing the flywheel housing. There was of course, a bolt which wouldn't move and naturally it had a chewed head thanks to my pitiful attempts to remove it. So I got angry :evil: produced my hammer and a 12mm socket and had it off and in the bin within seconds. :twisted: Just now got 6 bolts to remove the box and I will split them. :cool:
Cover off...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas019.jpg)
Clutch pressure plate...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas018.jpg)
... and ugly clutch (note awesome use of a shelf bracket as a flywheel-locking tool. I used to use a table knife but couldn't find it...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas020.jpg)
Almost ready to split
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas021.jpg)
Would have done it all but have a wedding to go to tomorrow so need to be ready for that!!
Well the gearbox is now off the block and has been put to one side for Shaun to take away. It was a bit reluctant to come apart at first. I thought this was a bit strange as the last 3 times I'd split an engine and box it had been easy. It was then I realised this was because I'd had an engine hoist to help... So rather than drive 15 miles to my friend's house I laid the engine on its side and beat the hell out of the join with a rubber mallet until it started to come apart. Gravity then took control and helped the box off :smiley:
The crank and pistons turned nicely in their bores so at least it's not seized. It's now on Ebay if anyone on here fancies rebuilding it? http://cgi.ebay.co.uk/Small-Bore-Classi ... 45fb77363d
So here it is, upturned on the sackbarrow ready to be taken to its new owner once the auction's over.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas024.jpg)
Close-up of the crank :)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas025.jpg)
Gearbox showing a rather alarming amount of sludge in the bottom... :shock:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas023.jpg)
Once the engine and box go I'll have a bit more room in the garage so may be able to get started properly! :laugh:
Well the gearbox is still here but pushing it under the rear of the car gave me a bit of room to wander round. Thought I had better clear out all the stuff that was in the boot (bags of spares such as a complete set of new brake pipes ready for bending, poly bushes for the tie-bars and engine steady, a top arm, two front hubs, a couple of lights, springs, an LCB, a gear selector and some small fibreglass panels). These have all been carefully stored away so Mr Clumsy here doesn't break them.
Someone had put an aerial on the roof at some point. I will need to replace it as the whole thing is a rotten mess. Lovely.
I then turned my attention to the interior. Oh dear. It is not pretty. The boot area appears to have lots of paint peelings in it but from what I am not sure. The front carpets are hideously damp and one of the mats in the car has what appears to be a new species of plant growing on it. All the seals are perished and need replacing - the sunroof being a case in point!! The dashboard is something I am really unsure about: as it's an early Midas I kind of want to keep it, but I don't really like it that much. Am tempted to modify it or make my own. The steering wheel is truly hideous and will have to go. As for those seats, they do tilt forward. I've never seen ones like them before and I do not know what they're out of - possibly an unusual 2+2 late 70's coupe. Mazda RX3? 260Z? Maybe even something like a Renault 17? Whatever, they're hideous and need to die. :evil:
Underbonnet is not so bad. The radiator is supposedly from an Allegro according to the previous owner but I'm not so sure. It looks like it's had a leak at some point so it'll come out and I'll hopefully get something newer from the scrappy which is about the same size but more efficient. Fusebox looks relatively new but I'm looking to move this inside the car so will probably replace it with one that'll take blade fuses. For some reason the choke cable exits right next to the battery area. That is going to be completely re-done as it's likely to get crushed where it is. My favourite though is the washer bottle and pump. Looks like it came from an early 80's Mitsubishi - I've never seen one before but it looks like a well designed bit of kit and one of the few parts I will definitely keep!
Boot area now clear:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas026.jpg)
It's nasty under those hideous seats :shocked:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas027.jpg)
New species of plant! :shocked:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas028.jpg)
Ruined sunroof seal :shock:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas034.jpg)
What to do with that dashboard???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas032.jpg)
Rad of unknown origin
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas030.jpg)
Battery Tray
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas031.jpg)
Aerial Stub :sad:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas033.jpg)
Funky washer bottle! :tongue:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas035.jpg)
The job list is getting longer... :laugh:
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Ok, Mrs B has allowed me some more time to go and play in the Man Room :smiley:
It was time to get the horrible carpets, underlay and soundproofing off the floor and see what's under there. Once I got my hands on it I reminded myself why I'd bought something made of fibreglass. That's right: if this had been metal it wouldn't have had a floor left!! On one side the seat bracket had disintegrated into the carpet. Very nasty. There's - still a bolt through the floor - I will grind it off in due course - I gently cut around the carpet rather than the bolt itself so I could lift off the carpet.
It was clear from one of the first things I found that it had not been used for a while: The tax disc...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas036.jpg)
I also found one of these; a punch for the rollpin on the gear selector. It's a bit rusty but I have always wanted one of these and used a succession of cheap watchmaker's screwdrivers over the years instead! :laugh:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas044.jpg)
There was also a fire extinguisher fitted to the driver's side. Not sure how stable it might be I carefully pulled it off the bracket. Health and safety is paramount in the Manroom: this was the result so I think it had been wet a while... :shocked:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas039.jpg)
The main carpet is now out and all the crap on it has been removed and binned. Is there anywhere I can get replacements? I'm not hopeful so am more than happy to try my hand at using the old as a template. I thought I might be able to start with a Mini front carpet and go from there.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas037.jpg)
The steering wheel was covered in black insulation tape so I took it all off and had a look underneath: it's an Astrali wheel with a wood rim (which has split). Wonder if it's worth anything to anyone?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas038.jpg)
There was so much horrible nasty damp underlay & soundproofing, some of which simply turned to dust. This a small percentage of it...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas041.jpg)
Still it means the interior now looks like this after being attacked with the Manroom hoover: 8-)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas042.jpg)
Will now leave things as I'm off to watch Mr Haye vs Mr Klitschko. With Chinese food. :drool:
Oh yeah I've still got the seats. Apparently they're genuine Midas items. They'll need a complete rebuild and retrim. If anyone can use them PM me as they'll be free. If I haven't heard by next week they'll be binned. :grin:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas043.jpg)
I thought I'd have a look at getting the dashboard out as there was bound to be more than a few horrors behind it. Amazingly, the fibreglass shell (with the middle bit which looks like a failed Star Wars character's helmet) came off really easily leaving behind another piece of fibreglass. However, this bit is bolted on at the ends so I won't be taking this off until the doors come off. It's also riveted to the main metal crossbrace so I have drilled out the rivets to make extraction easier. I'm still not sure about the what/how of the dash I'm going to use but hey, I've got time :rolleyes:
I turned my attention to the rest of the interior: the sill carpets needed to come out. Got as far as the driver's side seatbelt mounting and as I removed this I was a bit shocked to find that once the bolt was out water poured into the car! :shocked: I thought this was down to the drainage channels being blocked but further investigation revealed something else. There were two speakers in rear three-quarters so I removed them. The driver's side was nasty: it was stuffed full of underlay and old newspaper which was soaking wet, probably from the damaged seal on the small window. It dates from May 1981, about 3 months after the car was registered. A quick delve in with my hand revealed a couple of inches of water in the bottom. Still not sure how I'm going to get this out without a Vax-style hoover. We shall see. I can't get a spanner in to undo the seatbelts which attach to the rear heelboard - I need to have a closer look to see how I can do this without destroying the belt housing. I'm not going to use them again anyway, as I don't really trust a 30-year old seatbelt that's been sat in a damp car for 10 years, but I'd prefer to get 'em out the proper way without damaging too much! :evil:
The boot area was quite easy to get all the trim out of. The fibreglass side panels came out easily without a fight and even the big flexi pipe for the fuel tank was a doddle. I even removed the rear numberplate; Underneath is the cleanest part of the car. The seatbelt clips that bolt through the floor won't come out until I've got the Midas up on axle stands. I may be losing weight at the mo but I do not fit under there to get a spanner on the nuts. :undecided: There's a random small hole in the boot floor, and I have no clue why. Any ideas?
I also removed the front bumper (2 screws!) and had a quick look under the bonnet again. I am definitely thinking of a new wiring loom - possibly taking a Mini one and bridging / removing where necessary as the front loom does not look that healthy. More later :cool:
Dashboard under the fibreglass cover
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas054.jpg)
Horrid 1981 Sharp speakers which went straight in the bin
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas045.jpg)
Clean boot area
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas046.jpg)
Random hole in the boot floor
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas047.jpg)
Sodden underlay. This stank.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas050.jpg)
May 1981 Croydon Borough News (Wonder if they caught the thief?)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas051.jpg)
Clean interior but with seatbelts still attached
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas052.jpg)
The cleanest bit of the whole car!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas048.jpg)
Bumper gone in about 2 minutes and still in one piece!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas053.jpg)
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After 2 weeks enjoying the ridiculous amounts of pains au chocolat, Grimbergen Belgian beer and rain that Brittany had to offer, I realised it was time to head back into the garage and continue stripping! :kiss:
First up was removing the rear bumper. One screw was easy, the other of course had rusted solid. After 30 seconds with my trusty Dremel, it was off. I was mildly amused by the large amount of moss growing under it. I then turned my attention to the front lights. Headlight surrounds were not properly fixed so these came off easily. The headlights themselves were also easy, with just a couple of screws holding them both in. The surround on one is utterly shot to bits having rusted away. Finding a replacement may be tricky... I have discovered that they are different types; one has a sidelight whereas the other doesn't. Not too much of an issue as the car has sidelights and indicators below the bumper but these will need a freshen up too, given that the gaskets just fell apart.
I also removed all the clips holding the wiring loom to the bodywork in the engine bay so it "should" be nice and easy to take out. This of course will depend on how I get the dashboard out. It is more stubborn than Alan Sugar. I keep finding loads of hidden bolts (all seized of course) in really inaccessible places. Once I redesign this thing I'm gonna make it so it can be removed after undoing about 6 bolts. Poxy thing... I also decided to remove the heater which took the best part of an hour. Yup, you guessed it: seized and inaccesible bolts. It is in quite nasty condition so most of it will need replacing. I intend to replace the pathetic Mini blower with a Ford item (something I found on a GTM rebuild webiste) by removing the Ford fans and replacing them with the Mini items. The motor itself is much the same size so with a bit of persuasion (Hammer) I should be able to make it work :laugh:
Bumper off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas055.jpg)
Front lights off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas057.jpg)
State of front lights...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas056.jpg)
Rather knackered indicators and sidelights
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas059.jpg)
Loom ready to be removed once bl00dy dash is sorted
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas060.jpg)
Dead (ish) heater
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas058.jpg)
I have turned my attention back to the dashboard area. The bolts that hold the door on also appeared to go through the dashboard. The dashboard also seemed to be attached to the large piece of square steel tubing with heater ducting attached that ran the entire width of the car. I thought I would start here. As the dash had been riveted to this I thought it was simply the ravages of time that was keeping them together. WRONG!!! Having prised the dash front away from the steel tubing, it was this and not the dash that fell away. It wasn't structural at all and it appears that it wasn't used as any sort of eathing point. It was just where the heater ducting was channelled; 2 large pipes attach from the heater and holes in the top of the tube allowed warm air to attempt to reach the screen. It looked rubbish, and I shall endeavour to improve monumentally on this when I make my own dashboard.
I looked closer and there was a reason why the dash could not be easily removed. It wasn't just bolts holding it in place. It was fibreglassed into the car. I don't know if it was the original or not, but there was certainly some amount of modification over the years (badly!). There was also only one way it was coming out. Power tools. I immediately thought of my jigsaw but it was too big and bulky and the manouevrability would have been restricted. Dremel plus cutting disc (well, 4 actually) meant that after 15 minutes of steady cutting, the nightmare dash was out! Woo-hoo! :laugh: The horrible extended switch section in the middle will need further work but it had got to past 9pm and I needed a beer! :drool:
The dreaded dash, before things got ugly.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas061.jpg)
Weird way of ducting air.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas062.jpg)
It's gone! (Well most of it anyway...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas063.jpg)
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Before today, I was fed up with the inside of the car as I seem to have been making very slow progress. However, with a bit of elbow grease, my trusty Dremel and a lot of poking and prodding, I have achieved a fair bit this evening. :cool:
I cut off the stupid switch panel in the middle of the dash. This of course was much thicker than the other fibreglass and I went through 6 Dremel cutting discs. Lucky I've got a pot of 30+ :rolleyes: I then gave the dash area a hoover as it was gradually starting to look like a Colombian Drug Lord's "special" factory. :laugh:
I gave myself a challenge - to get the front wiring loom out and in a box without cutting any of it. First of all I pulled out all the underlay and soundproofing from the dash area. There was a shedload of it, and its condition was terrible - just like dead leaves as it fell apart in your hands. :sad: I pushed out the heater pipes. These will be thrown away eventually but I will take measurements first - don't want to buy too little of it when I replace it! I then started to poke the wires through having unclipped the rear loom. I started pushing it back into the car rather than trying to pull it out as it was clear that was NOT going to happen given the amount of twists and tangles in it. The underbonnet wiring was surprisingly neat by comparison. I have decided that it doesn't need renewing - it actually looks alot better than I thought on closer inspection; it was just dirty and badly laid out before.
Of course the Alternator plug wouldn't fit through the crudely hacked rectangular hole in the bulkhead so once again out came my friend Mr Dremel and a small "extension" was made. :evil: I intend to cover all the bulkhead holes and start again so I can actually furnish them with grommetts. I don't know who wired this car but they know less than I do. And my knowledge of electrics is "Red to red, green to green and blue to bits" :grin: Close inspection shows there was a hole in the middle of the bulkhead originally - this had been filled in and a couple of rectangular holes butchered on either side of the bonnet catch.
I finally have a clear dash and engine bay. I've now got Master cylinders, Wiper Assembly, Bonnet Catch and Radiator to remove in the engine bay. I've also got to finish stripping the interior of old glue and the remains of the underlay (yum what a nice job!! :( as well as take the rear lights out. Then it's glass and seals before starting on body prep. It's gonna be a long summer. I'm going down to Southern Mini Days soon so will scour the autojumbles for dashboard bits amongst other things. My wallet is wincing already :lipsrsealed:
Front Loom now out. Yay!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas064.jpg)
Clear dashboard area :grin:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas066.jpg)
Modified hole (new bit to the right). Lousy hacking job by the person who did it before!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas065.jpg)
Cleaner engine bay
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas067.jpg)
Managed to find half an hour this evening to take a look at the heater and establish whether it could be saved. I hoped that there was just a bit of surface rust and that the matrix was usable. Some hope...
I undid the screws on the outlet side of the heater. I say undo - I had to drill off two which had seized solid and already had chewed heads which I then made worse. I carefully prised off the side panel with a flat blade screwdriver and bingo! The matrix was proper knackered. Oh well... Guess I can get myself a secondhand heater in better nick from Southern Mini Days next weekend. I was able to remove the motor and fans though, which will enable me to experiment building my "Turbofan" Mini heater using a Ford Motor with the Mini fans and casing. The blower outlet was weird though - someone had made up a pipe reducer out of rubber and cardboard. It was fit only for the bin.
Side panel with weird pipe reducer. :undecided:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas068.jpg)
Heater with knackered matrix :angry:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas069.jpg)
Rustier than an HA Viva that's just crawled out of the sewer after 20 years in there :shock:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas070.jpg)
The starting point for "Turbofan" :wink:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas071.jpg)
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Not much done this weekend but have manged to strip down and destroy the horrible seats. Naturally this gave me a great deal of pleasure :evil: Some parts of the seats looked ok (some of the foam). The rest did not. Horrible, nasty and utterly rotten. Had to strip them down as the local dump (sorry - "Recycling Centre") won't take obvious car parts or seats for that matter. Plus I'd look like a right numpty trying to take just a pair of knackered seats to a breaker's...
So out came my friend Stanley and the "F" screwdriver. 10 minutes later there was a lots of crap and two metal seat frames which can go in the metal bin at the local tip.
Just foam and backrest left to go...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas072.jpg)
First one done
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas073.jpg)
That's a big pile of crap... :laugh:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas074.jpg)
Stripped frames (being guarded by Moneypenny the cat) :smiley:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas075.jpg)
Ok, so Saturday saw me off to Southern Mini Days in Kent with the sole purpose of picking up a few parts. So I now have some captive nut engine mounts, a pair of rear wheel brake cylinders, a gearshift gaiter, a set of caliper seals, a couple of stainless caliper pistons (for some reason known only to myself I didn't buy 4), a couple of dashboard vents and another heater, which the vendor assured me was in good working order and didn't leak.
However I put all this to one side as I wanted to clear as much stuff from the engine bay as possible. This meant firstly removing the wiper motor and wheelbox assembly. It came out nice and easily and was well lubricated but like most things on this car, it had suffered a bit with the 10 years of standing. It was a bit...well...brown. No problem! 5 minutes with my friend the angle grinder and wire brush had it looking good. I've put it in the corner out of the way.
I have also removed the bonnet stay which then got the same treatment and once I'd removed all the brackets and screws that didn't involve me needing an assistant, off came the bonnet. I then utilised the man-room hoover to suck up all the horrible dust, broken clips etc that had accumulated in the engine bay over the years. It still needs to be properly cleaned, but maybe I'll get on with that at the weekend.
As I still had a few minutes I thought I would just take a quick look at the heater matrix in the "new" heater. "Good working order" and "doesn't leak" eh? Thank you so much for relieving me of a tenner to take away some of your crap. The matrix was almost as bad as the previous one. :lipsrsealed: Guess I'll just have to bite the bullet and buy a new one - it's the only way to be sure... :rolleyes:
Wiper wheelbox before...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas076.jpg)
...and after!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas077.jpg)
Bonnet stay before...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas079.jpg)
...and after!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas080.jpg)
Bay getting cleaner
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas078.jpg)
Heater in good working order, allegedly. I beg to differ...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas081.jpg)
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Managed to get away from work nice and early today (bonus when you start at 7.30 - you can finish at 3.30 :smiley: )
Thought I would clear a bit more of the engine bay and set about removing the radiator. Now this was supposed to be an Allegro item - I think not as the top hose connection is on the wrong side of the engine bay. I think it's more likely to have been from something with an inline rather than transverse engine so possibly a Marina? Anyhow, undoing the 2 bolts on the front panel under where the bumper would normally sit was a doddle, presumably because they weren't rusty. The rad just lifted nicely out. It does look a bit knackered though at the bottom - a layer of rust probably means it's had a smaall amount of water sitting in it for several years and has started rotting out. Replacement is on the cards. If anyone works at a Motor Factors can they let me know of a radiator roughly 270mm x 500mm (excluding end tanks) that has a top and bottom hose connection on the left? Much appreciated :smiley:
The fan was bolted to the radiator by means of some extremely rusty bolts, 2 of which sheared immediately. These needed drilling out. I shall probably re-use this as apart from the rusty bolts, it looks in good condition.
Now the rad was missing it was easy to remove the wire mesh from the air intake - it was held on by 3 rusty wingnuts. The numberplate brackets were taken off (2 more sheared bolts...) I also took my time removing the weird engine steady bracket from the passenger side of the car. This took some time as the bolts and the bracket had become one mass of rust. Still, no match for my spanner and 2ft extension bar and socket. Apart from the various bolts that need to be released from inside the car via use of a helper, I am pretty much done in the engine bay now.
Rad out, rust at bottom... (rad is upside down...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas083.jpg)
Electric fan removed
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas082.jpg)
A gaping hole at the front now
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas084.jpg)
Strange bracket (broken). I'm sure those bushes will go again... :grin:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas085.jpg)
The pile of nasty, rusty seized bolts and knackered bushes from just tonight's work. :shocked: Stainless next time methinks...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas086.jpg)
I have been given an oil cooler by a mate (well I swapped it for some scampi tails...) but the scrap pipes on it were so solidly on there they wouldn't budge without extreme force. Now, as it's an OIL cooler and therefore has oil in it, heat would be a problem, especially with a naked flame. So I chucked it in a plastic bag and put it in the freezer overnight. Took it out this morning (after about 10 hours) and said unions undid easily. So that's my top tip of the day. :smiley:
I then got the heater I'd bought and thought if I am going to put a new matrix in it, I need to make sure it's not covered in rust and crap. So out came the angle grinder with wire brush attachment and I sorted the heater side panels no problem. However, the main heater body was scrap. I brushed of the paint and the wire brush went straight through. So that's another punch from me Mr Dodgy Mini parts vendor. Perfectly serviceable my donkey! :lipsrsealed:Amazingly the main body from the heater that had been left in the Midas for 10 years cleaned up ok, so I'll use that. Just need to sort some paint now...
Frozen oil cooler union
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas087.jpg)
Pipes off! Woo-hoo!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas088.jpg)
Rubbish heater, part 2
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas089.jpg)
Cleaned bits ready for paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas090.jpg)
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As it was a sunny afternoon it was time to push the little beast out of its brick prison and give the thing a proper clean - its first in about 10 years judging by the amount of moss and other interesting marks on it. Luckily for me my father-in-law runs a chemical company which manufactures car cleaning products (wholesale) and he has an excellent general purpose cleaner which will shift most things.
So I pushed the car out into the sun and taped up every hole which led to the interior. This would then give me an idea of just how shot the door and window seals were. So I spent the best part of 2 1/2 hours giving it a good scrub and hose down. I also was able to get an idea of the last few little jobs left to clear out the engine bay and interior, as it's not always apparent in the tiny garage I have. As I was cleaning it anyway, I gave the wheels a squirt of alloy cleaner to see how much work they'd need to refurbish. Still a lot. Ho hum...
And of course it all filled with water. My drive is on a slant, so it all collected in the rear. It took a while with a sponge to clear it out. The sun helped dry it out too. Still, it's now much cleaner (although still in need of a further deep clean) so will be nicer to work on. And I'm not too worried about the other marks as they're all going to attacked with an orbital sander and resprayed anyway!! :laugh:
Dirty Car!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas092.jpg)
Moss growing on the rear end...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas091.jpg)
Holes taped up in the front...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas093.jpg)
...and the back
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas094.jpg)
Bang! And the dirt is gone!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas095.jpg)
Clean!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas096.jpg)
Bonnet off and cleaner engine bay
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas097.jpg)
It's full of water!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas098.jpg)
Clean-ish alloy
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas099.jpg)
Back in the garage
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas100.jpg)
I have neglected the poor little thing over the last couple of weeks. I have been a busy boy but... It's all to do with not actually wanting to do that favourite of jobs, removing the split pin to get the master cylinders out. I will do it I promise... :lipsrsealed:
Had half an hour to spare this afternoon so got a couple of little jobs done. Sprayed up the heater side panels and the washer bottle bracket with some black Hammerite. There was also a pair of drive flanges in the box of bits I have, but one of them was attached to an old 8.4" disc. I removed the drive flange (damn I love that word :grin:) using WD40, a 1 1/2 foot long extension bar and aggression factor 5. It worked! :evil:
Parts ready for paint
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas101.jpg)
Couple of coats on (finish not too important - they're mostly hidden away!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas102.jpg)
About to get medieval on the flange bolts... :evil:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas103.jpg)
...which gave up without too much of a fight.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas104.jpg)
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:evil: Nice work bud :cool: :cool: :cool:
-
As I walked into the garage today I knew it was time. I could put it off no longer. The master cylinders had to come out. To anyone who doesn't know Minis that well, that means putting your head under the pedals, your feet where the back seats should be and using a pair of needle nose pliers to get to 2 split pins out of the most inaccessible place on the car. Or something like that anyway. So having given the heater panels and washer bottle bracket another spray of hammerite, I set about the horrible task that awaited my feeble skills.
It took about 4 minutes, one of which was contorting myself into position then realising my screwdriver was still on the workbench. The master cylinders were held in with "R" clips. All I had to do was push them out using the flat end of a screwdriver and then move the pins so they came out. I want to buy the man who put them in a beer! The master cylinders themselves need a refurb (no surprise there!) so I will have to put that on the Xmas list. Times is hard!!
I then set about removing the rest of the stuff in the engine bay that I could. This meant all bolts, brackets and heatsheilding. My Dremel went through 9 cutting discs going through all the rusty bolts that wouldn't budge, which was nearly all of them. The bonnet release cable and bracket was a particular pain as although I was able to undo the bulkhead bolts without any issues by jamming a spanner on the nuts inside the car, the bolts holding on the lever beneath the dashboard shelf were so rusty and inaccessible that cutting was the only option. It still took 15 minutes as I couldn't get the Dremel at the right angle due to the windscreen. I did annoy 2 earwigs which were living behind the bracket. They had to find new homes...
The heatshielding appeared to be a piece of carpet-like substance which had been siliconed to the bulkhead. This of course took ages to get off and had a collection of dead leaves and insects underneath. Tasty. The exhaust had obviously had an effect on the bulkhead in the past due to the scorched fibreglass I found. I will sand that out and build it back up before I figure out what sort of heatshield to use.
All the brackets are now off and only the pedal box and shock mounts remain until I can get the subframe off to attend to the brake and fuel lines. Could be a long time...
I love the man that put these in :laugh:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas106.jpg)
Master cylinders out (and needing a refurb!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas107.jpg)
Bracket held on by horrible silicone. What's wrong with a damn gasket?!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas108.jpg)
Horrible stuff behind the heatshield...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas109.jpg)
...which was also held on with bloomin' silicone!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas110.jpg)
Burnt bulkhead
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas111.jpg)
The collection of brackets and bars that came off. All need a clean-up and repaint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas112.jpg)
All the stuff for the bin. There's a lot of bolts which have been cut in half...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas113.jpg)
The engine bay is almost completely clear!!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas114.jpg)
Another spare half an hour and I thought it was time to shift some unwanted stuff from the garage, which just happens to be attached to the Midas. There were a pair of 4-pot callipers on the car (not plumbed in) so these have been unbolted and chucked on the bay of E to free up some cash for more bits. I'm sure the previous owner said they'd been refurbished but this may have been a while before it fell into my hands. They need to be redone.
As for the reason why I am not keeping them? There is no servo on my car; I don't want to have to shell out for a complete servo kit as a) I won't know its condition if secondhand, b) it'll be expensive new and c) the car weighs less than 750kg so 4-pots aren't really needed in my eyes. Standard 8.4" discs have always been fine on my last 3 Minis that had them, none of which used a servo. I've also got a second set of hubs I can recondition along with a pair of callipers and drive flanges. It's a no brainer! Plus standard 8.4" discs are cheap, even for the good ones!
4-pots on the car...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas115.jpg)
...and dismantled.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas116.jpg)
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The front end (other than the subframe and pedal box is now stripped so I turned my attention to the rear end. This meant the petrol tank. I didn't have an assistant for the day, so I thought first of all I'd stick a jack under the tank and tackle the bolts that were inside the car. I thought that as everything on this car was so rusty I might be lucky and they'd just shear off. Yeah, some hope. Of course they simply turned on themselves. As I was by myself, there was only one thing for it. Dremel cuts!
First of all I removed the screws at the back end. How I coped without a drill driver before I will never know. Two came out with no problems but the third was so crap it practically disintegrated and went through the mounting hole in the tank. Good enough for now :laugh:
Out came my friend the Dremel along with my favourite bit, the cutting disc (Or 4 of them actually as these bolts were particularly tough). I decided that as they were tough I would cut halfway through the bolts then give them a clout with MC hammer. There were no issue with the first 2, but the third was difficult (typically!). I was able to cut through it practically all the way then snapped it off with a pair of pliers.
All I had to do now was to lower it down using the jack which was surprisingly easy, with a little bit of manouevring and jiggling to get the filler neck through the boot floor. Condition isn't fantastic, but it does appear to be mainly surface rust. I will give it a clean up before making a decision on whether it needs replacing. The big flexi pipe definitely does!
Finally I needed to drain the tank so out came the funnel and fuel can. That and 2 fizzy drinks bottles as I ran out of room! 7 1/2 litres of some sort of fuel was left in it. Amazingly it doesn't smell "off" (I'm sure the car hasn't run since about 2001) so it may be usable for a lawn mower or strimmer. Think I've got a mate with one so I may earn myself a pint or similar. :cool:
Nuts. They just turned with the bolts...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas117.jpg)
Jack under the tank
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas118.jpg)
Dremel cuts. The bolts didn't stand a chance!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas119.jpg)
Lowering the tank.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas120.jpg)
Tank is out. Closer inspection required.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas121.jpg)
Potential lawn mower food
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas122.jpg)
I've been doing a bit of research over the past few days. It turns out that the previous engine which was in the Midas came from a 60's Cooper S and was fitted along with the 60's twin bolt subframe and the large alloy remote gear selector housing. The holes for the original subframe towers have been filled in and a later subframe fitted by previous owner Andy (thanks for your info) but the original rear mouting bolts are still there, rusted in place through the floor. These will be cut out in due course. Good old Dremel! As a result, the rod-change gear selector I have will need to be lengthened to sit properly in the car, and a chat with a friend revealed he would be happy to do this for me.
A twisted knee meant I couldn't do any crawling around under or around the car so I thought I would clean up and re-grease the gear selector I had before handing it over for modifictaion. So I hauled it out from under the bench and set to with a brush and some degreaser. It cleaned up fairly nicely, but I assumed it had a whole load of nasty going on inside as moving the gear leaver around didn't feel quite "right". So, once it was a bit cleaner (and smellier as my degreaser stinks!) I whipped the bottom cover off. My worst fears were realised: it was scrap. The gearstick sits in a cup which is held in place to the rod with 2 roll pins. One half of this one piece cup had sheared off. So I need a new gear selector before I can get it modified. Now where was I? Oh yeah - yeehaa...
Before its degreaser bath with years' worth of road grim and old oil on it. Yum...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas123.jpg)
The horrors inside.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas124.jpg)
And the offending part closer up (and clean!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas125.jpg)
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Ah the split pins :grin: :grin: :grin: :grin:
Ive been told I have to do them again on my mates project :angry: :angry: :angry: :grin:
-
Well, having been thwarted by my broken gear selectors, I thought I could at least salvage something by getting a replacement extension yoke for the gear lever so set about cutting the remains of the old one off. Unfortunately I ran out of Dremel Cutting discs halfway through this. It was irrelevent anyway as I discovered that the selector rod was badly bent. I could straighten it, but for less effort I could get another whole rod change assembly. Ho hum...
I then cleaned up the petrol tank. It looked like it was mainly surface rust so out with the wire brush and most of it came off; mainly bits of old paint and a lot of iron oxide. Still, a bit of rust convertor may go on this before I paint it with something heavy duty. I can't see any holes at all, but the piece of pipe I took off was well past its best.
I decided that as I'd painted the heater side panels I ought to take a look at the rest of the heater. The switch panel was a bit bent and the lever to move between "car" and "screen" was completely seized. I took everything to bits and cleaned everything up with the wire brush attachment on the angle grinder. I then was able to get the lever moving with use of the vice and brute force. I lubricated the little spring and dropped a dab of grease on the mechanism. It's now a lot better. The rest of the bits (including the main heater housing) were then ready to paint. I managed to do half the body then ran out of paint. Note to self: Buy more paint...
Bent rods
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas126.jpg)
Rusty tank
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas127.jpg)
Nasty Pipe
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas128.jpg)
Slightly cleaner tank
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas129.jpg)
Heater bits, before cleaning up
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas130.jpg)
Lever now working thatnks to brute force, grease and ignorance
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas131.jpg)
Cleaner bits
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas132.jpg)
Oh b******s - out of paint!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas133.jpg)
Still haven't bought any new paint, so left the heater bits for a while and turned my attention to getting the last of the stuff out of the interior. The headling (a one-piece bit of fibreglass) was going to need to come out, especially as I wanted to remove that horrid aerial stub. By the looks of things, all I needed to do was remove the gas struts (knackered) for the rear glass hatch and undo the four screws at the front to remove it. Simple! As the Haynes manual usually says, "Undo the screws/bolts/clips and lift out". What they don't have for their stripdown is a car that's been standing for 10 years in the damp. The nuts for the gas struts were easy; just use a 9/16" spanner to undo and they came away easily. The front screws? Well... One came out with no arguments. The other 3? Well let's just say that what should have been a 10 minute job at most became an hours' worth of struggle.
I really didn't want to get evil with the power tools, but after the first one came out, the other 3 just ended up with chewed heads. No amount of WD40 or shock treatment was going to make them move. I got some new Dremel cutting discs from Ebay last week and put them to use immediately. My plan was to cut off part of the screw and then just snap the rest of it off with a pair of pliers to avoid damaging the headlining too much. It was fiddly (because you're effectively working upside down, which I hate...) but 3 rusty and broken screw heads later the headlining fell on me. Only a few minor scratches around where it was screwed in. I will get the screw stubs out in time. No rush...
Well, the headlining had some strange mouldy bits on it and will get properly cleaned up in due course. For a moment I wasn't really sure where to put a 4ft x 4ft piece of fibreglass then I realised as it was so light the easiest place to put it was to hang it on the wall. 30 seconds with a hammer drill, rawlplug and screw, there it was. The aerial stub was stuck to a piece of aluminium, which was swiftly removed. Headlining out, sunroof and last bits of the internal loom will be next...
Horrible headling in place; sunvisors (one was already off) will need to be remade.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas134.jpg)
Gas strut undone
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas135.jpg)
It's out! You can just about see the rusty screw stubs...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas136.jpg)
Nasty aerial stub and bit of ali.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas137.jpg)
The headlining's new home
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas138.jpg)
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It has been a bit of a frustrating time this weekend. I have bought a couple of bits and found a nightmare scenario.
Got some more paint from the bay of "e" and proceeded to give the heater parts another coat. Don't worry - they look significantly better than the photograph - it's the harsh light of the flash that makes them look far worse than they actually are!! The heater bits are going under the dash and won't be seen much anyway so I am not too bothered as I can't see it - as long as the blooming thing doesn't leak...
I also bought a handbrake (the old one in the car appears to be rustier than some of the bolts that are holding it in place and appears to be missing its release button. The one I've got is a Sportpack Mini item which I picked up for less than a tenner including postage and it looks in almost perfect condition. Superb. I have narrowly missed out on a gear selector though (don't you just HATE it when you'e outbid by 50p??).
As I'd received a headlight bracket through the post as well (Thanks Graham), I thought I would prepare that for paint, along with the other headlight bits I have. Unfortunately that was where my nightmare scenario raised its really ugly head. I have (just about) two usable "holding brackets" for the headlights and two trim brackets as well. However, the backplates are more of an issue. I have one very solid one, and... well I'll just let the pics do the talking. If anyone's got a headlight backplate for a Mk1/Mk2 Midas (it's Austin Allegro for those that don't know) in usable condition please let me know asap. Mine are completely fubar'd. B******s. :cry:
Painted stuff - it looks much better in the flesh!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas139.jpg)
The headlight bits I had to play with.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas140.jpg)
Some of the bits I didn't use...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas141.jpg)
And the paper-thin backplates. Ouch!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas142.jpg)
Aside from the tragedy of the headlight backplates from last weekend, something worse has happened. The stereo in the garage stopped working. I like to listen to the radio or CDs when I am working on the car, as it is something I have always done. The old portable (which used to belong to my Mum after she won it in a competition in about 1994) had finally given up. It refused to play tapes (remember them?!), cds and only wanted to occasionally tune in to the radio. Must have been all the abuse carried out in its vicinity... My wonderful friend Liz came up trumps with "something she had stashed in the spare room". An Aiwa mini hifi that plays CD, tape and Minidisc (Not that I'll use it...) Works perfectly and has remote control. That'll do! So it was pressed into (loud) service and seems to be doing very well. Top job!
As I had come across so many issues with the front lights, I thought I would see if I could find anything equally as poor at the back end of the car. I started with taking off the last piece of fibreglass trim just under where the rear hatch sits. 4 screws would generally take about 2 minutes. However, this is not a "normal" car. I keep forgetting that it has been standing 11 years. 2 screws came out with no bother. The other 2 required a bit more work and eventually were unscrewed using pliers after attempts with screwdrivers and drill drivers failed. I threatened to use the Dremel cutting discs, but was able to get them moving with sheer brutality instead.
The rear lights were next. Of course, just undoing a few bolts is easy... Yup, the old issues of car that has been standing 11 years raised its ugly head once more. Several of the studs snapped in their mountings and 2 of the screws had to be cut off with my old buddy Dremel. Once this was done however, the lights lifted out with a bit of persuasion and I was able to split them on the workbench. One looked horrible, the other looked worse... I am not sure if I will be able to modify the lenses to support new studs somehow or if I will need new lenses. No harm in trying I guess.
I also tried to undo the t-piece that holds in the spare wheel. And of course it had rusted to the glassed in nut which then broke its mounting and just turned. And of course there was no other way to remove it than to cut it out. So out came the Dremel again. I cut the rusted nut off, but I'm not sure I am going to use the t-piece again - I may come up with something different. Watch this space on that one.
The petrol filler pipe needed to come off too. This had 3 screws to remove. 2 were easy. 1 was not. Brutality happened again. Dremel cuts... I am undecided whether to try to find another TR7 cap or not as mine's broken. Any suggestions as to what else might fit and look "right"?
Finally I won an ultimate engine steady on ebay which will help with keeping the engine in the car. It has been modified slightly by someone cutting part of the side panel off, but it's certainly usable and it only cost a fiver. I'll tidy it up and go from there.
Old faithful. Goodbye old friend...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas144.jpg)
New sounds. Bigger speakers too... :laugh:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas143.jpg)
Rear hatch panel out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas146.jpg)
Butchered screws
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas147.jpg)
Rear lights out. Looks weird without them.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas150.jpg)
Light units before splitting.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas151.jpg)
... and split, looking ugly. This was the good one.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas152.jpg)
This was the not so good one... What's been growing in there???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas153.jpg)
"Hump" where the spare wheel t-piece broke off. Neatly cut open with Dremel to retrieve...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas155.jpg)
...broken and very rusty bolt.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas156.jpg)
Dremel cuts!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas157.jpg)
Fuel cap (broken) and pipe
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas154.jpg)
Modified engine steady. Needs new bushes and a tidy up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas145.jpg)
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It's amazing what you can find on Ebay. I now have a fully usable pair of headlight backplates along with all associated retaining brackets and trim rings. As I have been a bit stuck for time these past few days, all I have had time to do is strip all the paint and rust off and give them a coat of Hammerite.
I now have the rather daunting task of taking off the doors, removing all the glass and taking the rear beam off. Condition is unknown... :shocked: By the way, any tips for where I can store the glass?? Mrs Bounce says no to "in the house"... :laugh:
The best of the headlight brackets etc before stripping
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas158.jpg)
...and after paint (along with a couple of bits of heater).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas159.jpg)
Since I got the Midas home there have been loads of 1275 engine bits in boxes and crates which I've ignored. As I was fed up with grinding rusty bolts with the Dremel and cleaning things with the wire brush attachment on the grinder I cleaned up the bench and had a look to see what I had to play with. Andy, the previous owner, said it had come out of a Metro and one of the pistons had seized.
I laid most of it on out the bench and came to the following conclusions:
It is a standard 1275 Metro engine with standard size head and there's absolutely nothing special about it that I can tell (with my limited knowledge of engines in bits..). The bores look in excellent condition; the crank appears to be pretty much good to go again with just a clean up; the cam looks pretty standard and the followers do have a bit of pitting on them. The rods could do with a bit of a clean up but I think I will need to do the following:
Take the block, head, crank and pistons to an Engineering Shop and speak to them about what would need doing for a rebuild. There's no sense in just buying another engine of unknown quality from ebay or the small ads when I can spend that money (plus a fair bit more!!) and know exactly what I am getting. I have no intention of building something stupidly powerful (1380, twin-cam etc) as I don't need anything that pokey. I simply do not have the necessary funds to do that in one hit and I'm not prepared to get into debt over this. I would love to go to Swiftune or MED and give them a couple of grand for a few billet bits but I am the sort of person who wouldn't notice once the engine is running and I would also never recoup the money. No, just a warmed-over 1275/1293 with a decent head and cam should suffice for now and hopefully give me 80-odd bhp. I might get the flywheel and backplate lightened and balanced though.
I'm thinking only rebore if necessary, new pistons, cleaned up and balanced rods, lightened flywheel and backplate, new bearings and a reconditioned head with a bit of porting and bigger valves and a hotter camshaft. I will speak to the engineers and ask their advice on what I have.
The block is now bare apart from the core plugs, the cam followers and the funny brass bungs that you locate the gearbox with. I'm going to spend a while with the degreaser and paintbrush to clean off all the gunk from all the components.
All the dust from a couple of days' wire brushing (watch is there so you can gauge how much there is...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas165.jpg)
Engine bits on the bench (seized piston without bag)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas161.jpg)
The block (before removing pump, studs etc) which desperately needs a clean!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas162.jpg)
Standard camshaft. This will be replaced with something a bit spicier.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas163.jpg)
Block from the bottom. You can just about see the followers with a bit of pitting on them. Clean bores.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas164.jpg)
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Well it's been a bit of a while since I last went into the garage to actually do some work on the little beastie. I guess doing too many social things along with colder temperatures etc meant I put it to the back of my mind... I had an hour to spare so I thought I would attempt to take at least one of the rear drums off and have a look at the rear brakes. So I got myself some wood, an axle stand and the trolley jack and gently put everything safely up in the air having loosened to the wheelnuts.
What greeted me behind the wheel was a rusty looking drum; I grabbed the impact driver as I was sure the retaining screws would be utterly seized. Erm... no! Nice and easy to undo with a simple screwdriver. I was gobsmacked! Before I took the drum off I had a quick look at the spring & shock and the surrounding area. What looked like star-crazing in the fibreglass at first glance was in fact a spider, but the spring and shock looked like they could do with a fair bit of attention. I reckon they are probably the originals and will definitely need a full overhaul.
Amazingly the adjuster worked fine too. I am absolutely certain that this has been looked at recently. There was evidence of the cylinder leaking and the shoes seemed to be different makes, but everything seemed to be working fine. Even the inside of the drum looked pretty good. I will obviously replace all the consumables (I already have the replacement cylinders) and will clean up the drum before giving it a coat of paint. I will also be paying special attention to the rusty looking backplate! Now all I have to do is make sure the other side is just as easy to remove...
I removed one of the rear mudflaps when the wheel was off the car - I have never seen one of these before - marked "BLMC" so it's likely to be from a late 60's vehicle but what? Are these likely to be worth anything? Not sure if I am going to be keeping them or not. They're not Midas items as far as I'm aware.
Also have a bit of an annoying issue; I only have 3 centre caps for my lovely Mistral wheels. If anyone's got one kicking about in a box somewhere then please let me know! They don't look the easiest thing to replace and I would rather have all 4 than take 3 off as they're quite nice.
Also found the pictures from when I originally picked up the Midas in June so I've included these for your viewing pleasure :cool:
What lies behind such a pleasant exterior???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas172.jpg)
Rusty drum...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas173.jpg)
Got to be the original!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas174.jpg)
Doesn't look too bad, and everything moves!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas175.jpg)
Evidence of fluid in here...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas176.jpg)
Odd shoes... (they're not the same manufacturer!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas178.jpg)
Mudflaps. But from what?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas179.jpg)
I love these Centre Caps. But I only have 3. Can you help?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas180.jpg)
Picking up the Midas from deepest darkest Eastleigh (which was wet!!). Road train!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas167.jpg)
Andy, the marvellous guy I bought it from. Top bloke! Although he looks upset to see it go...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas166.jpg)
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Apologies to everyone who keeps tabs on this project - I have been a busy boy and haven't had much time for the garage. Shame on me.
There have been bits of engine sitting on the bench for a while now and it is time I did something with them. So I thought to myself: "What will an engineering shop need to see?" I have the block (with big-ends attached), crank, old bearings to determine size, pistons, rods, bare head, and the flywheel and backplate. I loaded these heavy bits of metal into my trusty Bora's boot (big enough to swallow 8, possibly even 10 12" wheels with tyres so no problem with this lot!) and am about to head off to a couple of engineering shops to get some quotes; the bores look good but I am no expert. I'll get some idea of the cost of a new set of pistons (next size up if needed) with a higher compression, full balancing, possibly lighten the flywheel and backplate with all new bearings and a much modified version of my head. Then I will start saving. Eek... :shocked:
I want to recondition the Mistral alloys (still after a centre cap to replace the missing one as I only have 3...) but to do this I needed to make a frame to move the shell around on (this will probably made in due course) or buy some more axle stands. Or get myself another set of wheels. Thanks to a very helpful user on The Mini Forum (Cheers Matt!) I was able to get hold of a set of 4 steel wheels and tyres for the grand total of nothing. Nada. £0. Christmas has come early! So the alloys were whipped off and replaced with the steelies. I'll get the tyres taken off then have a look at getting all the paint and dirt off the alloys before painting. I am thinking black/polished rim to be a good contrast to the colour I am thinking of painting the car (Orange)... Any other suggestions?
Block on bench
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas182.jpg)
Crank which looks good generally - I am hoping that it will need nothing more than a polish.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas184.jpg)
The very standard cylinder head. This will not look like this by the time I'm done with it. Expect bigger valves and porting.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas188.jpg)
Standard size low compression pistons. Not long for this world...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas186.jpg)
Old bearing shells and cam followers - they were just in the same box - and there are 4 more followers and plenty more bearing shells!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas185.jpg)
Flywheel and backplate. Time to lighten???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas187.jpg)
Free steelies!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas181.jpg)
Alloys now off the car awaiting removal of the tyres.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas190.jpg)
Looking like a proper project now with dirty steels...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas189.jpg)
Went to Clacton and popped into a small, family-run engineering shop I have used before. They did an excellent job making my old Mayfair head Unleaded-ready about 12 years ago, they've been going for 43 years plus I went to the same junior school as the guy who now does most of the work (his father who started the business appears to have taken a back seat). They have taken the block and crank to have a decent measure up and will give me a quote next week. They said the block may just need a hone but there were rust marks that might not come out. For the sake of a few quid I think I'll go for a rebore anyway as the pistons will be replaced as a matter of course; the ones I have are of unknown quality and are low-compression. Will keep you posted.
Ok, so now the Christmas holidays and the delights of all that came with it (a full set of braided brake & clutch hoses plus a fuse box for the Midas, 108 Jaffa Cakes and the Novovirus) are now over it was time to get back into the garage.
I am going to be using the older, non-verto style of clutch but with A+ drop gears; this will enable me to not have to faff about changing the first motion gearwheel to suit the A-series drops. I have both the A-series and the A+ flywheel housings; and yes of course there was a problem. It looked like the A+ housing had been repaired with chemical metal or similar around where the starter motor sits. A light tap with MC Hammer and my fears were realised. It fell to bits and is therefore useless. I have another A+ housing (for scrap), which has also broken in the same area. Is this a common problem?
So I have two options open to me. 1) Change the gearbox first motion gearwheel (not tempting I must be honest) or 2) Get another A+ housing. My good friend Shaun seems to think he has one in his garage. I will wait and see... :)
Once I had spent about 3 hours tidying and moving stuff around the garage (it was long overdue believe me!) I had a quick look at the nearside rear drum; I wasn't able to get round there before cleaning up so I was hoping that it wasn't going to be too bad. The adjuster was seized solid and the amount of rust on the drum and surrounding area did not fill me with confidence. However, some WD40 and a bit of wiggling with the brake spanner soon had it freed off and the screws once again came out easily. There was evidence of copious quantities of Copperslip grease in there so someone had been there before me! No obvious leakage and also the shoes looked pretty new. I wonder if previous owner Andy had done one side before calling it a day on the project? The rear brakes will be completely rebuilt anyway, so provided everything else comes apart easily enough (ha ha! :grin: ) I do not envisage further rear brake issues.
Broken flywheel housing with chemical metal bodge.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas192.jpg)
...which now resides with its mate outside.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas193.jpg)
Loads of rust!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas195.jpg)
Seized adjuster, amongst other things...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas194.jpg)
Shoes out, lots of meat on them. Had they even been used in anger?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas196.jpg)
Christmas Prezzies!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas191.jpg)
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I have to admit that I am starting to get annoyed with this project. Seemingly simple things can really get on your nerves and make you question why you're doing it. Enjoyment? It doesn't really seem so at the moment... :lipsrsealed:
I managed to get down to the tyre place (X-Spurt tyres in Ipswich - fantastic guys and reasonable too) who took the tyres off my 5 Mistrals. I am glad I wasn't planning on using these tyres: 3 had very visible cracks and according to the dates on them the youngest was 14 years old. The spare (an ancient Michelin which also had an inner tube) was 22 years old! :shocked: They all fitted easily into my trusty Bora's boot. Unfortunately it's a VW, and not a Maserati... :grin:
I received a nice parcel from Bilt-Hamber which contained some of their De-ox-C rust remover and also some of their De-ox Gel for those things too big to go into a bucket. It was this I was going to use for the petrol tank. So out came the wire brush and I did the final once over before wipedown and wash which you need to do before application. The tank leaks. Tipping it on to its side showed it dribbled out by the seam. I am not one to do a bodge on a petrol tank, so it will need to be replaced. Mini Van/Pick-up/Estate tanks aren't cheap new (£110 +) so I will be on the lookout for a secondhand one once funds allow. B****cks!
To try to calm me down I mixed up 10 litres of Deox-C and threw in a load of stuff that has rust on it to see what happens. This included my cylinder head, which is in a bit of a poor state with loads of rust in the thermostat area. This head is either going to be highly modified (it's a standard Metro 12G940) or not used if I find a half decent head at a very decent price so I don't mind experimenting with it.
I also thought I needed to start stripping the final part of the interior, namely the door cards. Off came the window winder and the broken door pull. I really don't like these so may look into a different way of pulling the door shut when it gets rebuilt. The door pocket came off with no issues at all. Wow! That left the 5 screws on the door card itself. The first 4 were no trouble at all with a little persuasion. But of course, there's always one. The bottom front screw would not move and started to chew up. I first thought I would try drilling it, but then remembered just how tough this had been before. Out came the Dremel and I ground a fresh slot in the screw for a flat-bladed screwdriver. Thankfully this worked and I carefully wound the screw out.
What I found underneath was pretty much as I expected. A little bit corroded here and there, with some sort of nasty moss growing in the window channels; a legacy of the car standing in the damp for 11 years. I will drill out the rivets on the rusty plate and see if it is salvageable. If not, I'll simply make another, probably out of aluminium. Will write more when I feel less annoyed...
Wheels in boot
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas197.jpg)
Leaking tank. Whoop-di-doo.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas198.jpg)
Tub of De-ox-C with brackets and a head de-rusting overnight.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas199.jpg)
Mr Door Panel, it is time for you to be removed!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas200.jpg)
Broken Door Strap with enormous screws
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas201.jpg)
Not-too-shabby door pocket
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas202.jpg)
Poxy screw, which came out after "modification"
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas203.jpg)
Plastic covering, held on with very powdery gaffa tape.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas204.jpg)
...and the rusty stuff underneath. Yay...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas205.jpg)
Everyone has good days, and everyone has bad days. Guess which one I have had? I have spent an afternoon in the Manroom and it has been one of frustration. Thought I would tidy up some of the last little bits in the interior before getting set to take the doors off and glass out. The Deox-C rust remover bath had worked very well on the small items I had immersed in it. The Y-piece from my LCB was somewhat brown, and after a soak and a scrub it really did remove most of it. More severe scrubbing would have probably removed it all. Impressive stuff.
There were other issues to contend with in the interior however. The front subframe was originally the older, solidly mounted twin-bolt item (which had a Cooper S engine attached to it), but this had been removed and after some minor surgery, a newer single bolt item had been mounted in its place. The original floor bolts had been left in place as they are in a different place, a couple of inches further back on the floorpan. And because they'd been left in place, they had got damp over the 11 years of standing around. Damp = rust. Yup, no longer recognisable as bolts and washers, they had become a small mound of rust-covered metal. No problem, I thought, and brought in the Dremel. This time however, I was thwarted. The cutting discs are very thin and were no match for the seemingly huge amounts of crud that had accumulated over the decade or so rusting away. After I had broken my fourth cutting disc, I thought I would try the angle grinder. I only had a grinding disc though, and quickly realised that this would do no more than set the car on fire with the extended use I would need to grind the bolts down. I left them alone and will come back to them with an alternative plan of action, by cutting them off from the bottom up once I get the car in the air.
After a generous soaking in WD-40, I managed to remove the rather knackered handbrake lever and the rear cable that attaches to it, which also shed a vast amount of rusty nastiness all over the interior. It doesn't look like a Mini cable - I will have to check in the build manual to find out what it is from. There were also the bolts attaching the seatbelt stalks, which looked like they had captive nuts on plates underneath. I managed to get them halfway out then of course said "captive" nuts were no longer captive. Without an assistant to hand, getting uder the car and in the car simultaneously is impossible so once again I will wait until I can get underneath easily. I do have a plan for this which will be revealed in due course. :smiley:
I did have a quick look underneath whilst looking to see how to remove the actual seatbelts themselves, which looks nigh on impossible unless you've got a very strange shaped spanner. I got Mr Screwdriver out and had a good poke at the rear beam. It seems to be in fairly good nick, which probably means it'll fall to bits when I get it off the car... :rolleyes:
One day this car will have no rusty bolts or screws on it and will be being rebuilt instead of stripped down... I think I will leave it for now and ignore it for a week. It is annoying me for silly reasons. Maybe I should have set it on fire...
Rusty bits now not so rusty...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas210.jpg)
Rust lumps on the floor back from the "new" subframe bolts. Poly mounts showing through!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas208.jpg)
Not much better, and you can just about see the remains of all the broken cutting discs.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas207.jpg)
Finally got the handbrake cable off, which shed rust everywhere.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas206.jpg)
...and the lever finally came off, after two of the toughest, rustiest nuts on the car (which still resemble nuts...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas209.jpg)
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After the delights of last weekend, I needed to have a good day. I feel like I have achieved a lot today and I feel all the better for it :smiley: I had been putting off a horrid job for ages, and as I was concentrating on the interior anyway, I thought it best to get on with it.
The sides, sills and footwells were covered in the remains of some horrid sort of foam cloth, which had obviously deteriorated over the 11 or so years of standing idle. Did I have a suitable power tool to remove it? No. So out with the wallpaper scraper it was. It took 2 hours. Still, a pint of Dr Pepper, several Jaffa Cakes and a lot of scraping and swearing later, it was all off. And in the footwells. So I emptied the Manroom vacuum and sucked up everything I possibly could from the floor. All except that large piece of underlay which had been stuck to the bottom of the dash shelf with what appeared to be underseal. It was disgusting...
I also took the time to properly remove that horrible old aerial which ran through the sill into the wiring loom. I cut the old stub off so it would pull through more easily and threw it all away, along with the doubtless useless by now speaker wires.
I then dug out the "new" Mini handbrake I'd bought from Ebay. The plan was to simply swap over the connection on the back but when I put them side-by-side, I realised that the brackets and the holes drilled to mount them were totally different. I really didn't want to go back to using the nasty old handbrake as it had no usable internal release mechanism - the missing button was a good indicator of this! I also don't know what the handbrake lever was from - I am guessing something like an Allegro so I am not planning to try tracking a direct replacement down.
After a bit of lateral thinking and measuring, I realised I could use one of the mounting bolts by making a bracket and mount the rear end by drilling one hole and using a 1 1/4" spacer. I cut the end off the bottom mounting bracket I had for an old A-series weather shield and smacked it about a bit in the vice until it was the right shape. What to use for a spacer? I had an old chrome steering column drop-bracket in my "bits" box which was looking a bit pitted but was otherwise fine. A bit of cutting and shaping with Harry Hacksaw and my trusty Dremel had it exactly how I wanted it. I cleaned up the connection and all seems to fit together nicely. I will drill the hole properly once the subframe and beam are off and the car's in the air.
I now feel like I am getting somewhere :smiley:
Horrible nasty foam cloth
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas215.jpg)
All scraped off and on the floor
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas211.jpg)
Hoovered out (again...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas212.jpg)
Aerial finally removed!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas213.jpg)
Aerial stub. I reckon that can be used again... :grin:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas214.jpg)
Handbrakes together, with very different mounting brackets...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas216.jpg)
Modified Mini handbrake with spacer and scratchbuilt bracket. Bolt is not the one I will be using!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas217.jpg)
An interesting day today. I picked up the block and crank from the Engineering Shop after waiting 3 weeks for a phone call that never came. He had the quotes ready for me but hadn't had the time to call, so he said. I know I said that there was no rush but 5 weeks in total just to get a quote is rather poor. When it comes to general engineering he is pretty good, but show him anything specialist and I think he struggles. He does think the crank will only need a polish though.
It was always my intention to get more than one quote and I chucked everything into the boot (except the camshaft) and headed off to see my preferred engineer. I spent a while chatting to him about my needs - he remembered me from when a friend and I had popped in for a couple of valves 10 years ago! He made some interesting discoveries when he looked at what was in the boot. The engine block itself is in pretty good nick; the cam bearings will need to be replaced and a rebore would be best as there are some rust marks (which I already knew about). He agreed with the other shop about the camshaft possibly needing just a polish.
The interesting details were the cylinder head and the flywheel. The head has definitely seen porting work - he thought it was a pretty good job - although the valves were still standard size. He thinks it had been set up for turbocharging (not my intention) as the chambers themselves were quite large. I had thought it was a standard low-compression Metro engine, but because the head has seen work it's likely it wasn't the original one. The flywheel was the non-verto item I had taken off the spare engine that came with the car. He took one look at it and told me it had been lightened. It's not superlight by any means, but is certainly not a standard weight. :cool:
I have explained what I am looking for and he'll give me quote later in the week. This means: rebore, new higher-compression pistons, polish crank (regrind if necessary), new bearings, thrusts and cam bearings and a bottom end balance. As an aside I am also looking to have the head changed to match with larger inlets (possibly bigger exhaust valves too), hardened inserts and having the inlet manifold matched to the ports. I think it's going to be expensive!!!
I have however discovered that my A+ Primary Gear has deep scoring on the inside and will need replacing. Why didn't I know this on Sunday when I was at Bingley??? As far as Bingley goes I picked up a few small items, including a roll of soundproofing, an A+ flywheel housing, a fuel gauge and a cheap steering wheel so I can sell the Astrali to someone who can mend it...
Dodgy A+ Primary Gear with deep scoring. I need a new one. :rolleyes:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas218.jpg)
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Cracking work, keep at it :afro:
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First job today was to clean up the absolutely filthy flywheel housing that I picked up at Bingley. I think it had at least 10 years' worth of grime on it, so a single clean was always going to be unlikely to sort it. That said, I gave it a good dunking and scrubbing in some of father-in-law Steve's degreaser and it has done a pretty good job. I will still need to give it another go but that will be at a later date.
Anyone who has used a standard Mini heater will know that the blower is rubbish. I have been given some suggestions to what I could do, one of which was to transplant a completely different heater into the car - not ideal as there's not a lot of space. I found my answer on a website where a guy has restored a GTM Coupe (http://www.ken555.plus.com/gtm/) - he changed the Mini Heater blower for one from a Ford Sierra. Some surgery is required - changing the fans over for one, but all in all it looks very doable, and I should be able to incorporate a multiple speed switch removed from something in a scrapyard.
I won a Sierra blower on eBay for 99p and proceded to remove it from its housing. It is slightly wider (once the double fans have been removed) but should fit within the housing with a little jiggery pokery. Getting the Mini fans off was easy - with a bit of WD40 they simply twisted off. The Ford fans were somewhat more difficult, but a bit of work with the Dremel had them on the bench. The next issue was the size of the spindles - the Mini spindles measure 6.5mm, whereas the Ford items were just over 8mm. Out came the drill and I gradually drilled out the centres to first 7, then 8mm. They went on with a little bit of persuasion, but unfortunately I wasn't concentrating and managed to destroy one. Luckily for me there was a spare from the other heater. I was a bit more careful with this one... I used the original blower mount, screwed to the remains of the Ford housing to mount it. Time ran out so it's yet to be finished, but a quick reassemble shows it still needs some work. More to follow...
Disgusting housing. Loads of road grime and old oil.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas220.jpg)
Something tells me there was an oil leak in there once...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas221.jpg)
Well it's a bit cleaner now, but needs more work.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas222.jpg)
Sierra Blower, from a Cosworth, allegedly.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas219.jpg)
Big fans vs little fans
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas223.jpg)
Fans removed
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas224.jpg)
Big spindle
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas225.jpg)
Little spindle
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas226.jpg)
In the Mini housing, still with most of the plastic Sierra housing attached
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas227.jpg)
Using the Mini bracket
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas228.jpg)
Broken fan. Oops... :embarassed:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas229.jpg)
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Am not happy with the heater mods that I've been attempting. The Sierra motor doesn't quite fit properly and there's no real guarantee it'll be anything more than a bit of a bodge job given my limited skill. So the plan is to get out the tape measure then go hunting in the scrappy, bringing back a heater, blower, associated pipework and half decent vents that I can incorporate into the dashboard designs that I have running through my head.
Haven't been in the garage much as although I have a heater, it's still been a bit chilly so have stayed inside. I did however manage to get some more funds for the project. Remember this?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas038.jpg)
The old wood-rimmed steering wheel (wrapped in electrical PVC tape when I got it) where the wood had split? The one I didn't particularly like anyway? Well I cleaned it up (it was an Astrali wheel & boss) and chucked it on eBay to see if anyone wanted it. 3 people did and had a bidding war. It eventually finished at £113, so that will help pay for the replacement fuel tank, if nothing else. More later :smiley:
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Well, I haven't done a lot recently due to losing heart. However, having kicked myself in the head to knock some sense back into my thick skull, I have been acquiring bits and will soon be back on the project with a vengeance. I now have some new rear brake shoes, a half decent brake master cylinder, a new bottom steady bar, a K&N air filter for my HIF44 SU, a decent quality set of indicator/wiper stalks (at a really good price!) and also a fuel gauge. Some came from the Mini Show at Bingley, whereas others found their way into my possession by means of noticing adverts on various forums and of course Ebay. Everything will be cleaned up and reconditioned if needed and carefully packed for when it's time to rebuild.
Parts on workbench
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas230.jpg)
I also have a new something for the engine bay. I won a big-valve cylinder head on Ebay after the winning bidder didn't read the postage details properly. He lived in Italy. I don't. I win. I love second chance offers :laugh: My original head which came with the project is bare so new valves would have been needed at some point. It is also low compression so would have taken some mods to make it half decent for a normally aspirated engine. I briefly considered turbocharging, but the funds are letting me down at the moment. I would want to do it properly, which just isn't an option. At the moment, anyhow!! I haven't had a really close look yet but it may be that someone's had a little go in the ports. It's my 40th birthday soon (The Midas was an early prezzie from the wonderful Mrs Bounce) so I have asked for everyone to contribute to the engine fund rather than get me gifts I may not want. Things may ACTUALLY be starting to happen!! :cool:
Here's the head!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas231.jpg)
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Don't give up when its done it will be even more worthwhile :smiley:
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Don't worry Rich - it's all good - just got a bit fed up at one point!! :laugh:
We popped to the scrappy this morning to see if there was anything worth using as a replacement heater, but even on the smaller cars they were either massive or buried deep in the dashboard. I might pop down to a different scrappy in due course as they have items off the shelf I could look at. No rush for now. All was not lost though as my friend who I went to the scrappy with had an idea for my switchgear & dials - from an XJ6. I like it. Will figure out some way of using most of it to go into the dashboard design that's currently evolving in my head.
Meanwhile, back at the Manroom I still had that new-found enthusiasm so I set about removing all the glass. As all the rubbers are going to be replaced I had no qualms about using "my friend Stanley" whenever the need arose. The side 3/4 windows were first. A quick poke with a screwdriver removed the trim in the centre of the rubber then I cut down one side of the rubber. I was easily able to push it out; I then repeated this on the other side with equally successful results.
Next up was the rear hatch. This was secured by 2 bolts each side which go through the body into the higes on the outside. Let's just say I am probably good at the game "Snap"... All 4 bolts went but it did of course allow me to remove the hatch. I've taken the hinges off and will look at drilling out and retapping the threads where the bolt shanks currently sit. The hatch has been carefully stored by the fridge...
Moving swiftly on to the sunroof - I was on a roll! However, I needed to figure out how it was attached as it was not clear by any means. After some investigation I found the outer frame was screwed through the roof to little plastic triangular brackets, but firstly I had to remove the (knackered) seal on top of the screws, which was held in place by mastic. Amazingly, every single screw came out easily. And there were an awful lot of them! Once they were gone the frame simply lifted out. I had to use the scraper to get the remaining sealant off the roof. Nasty stuff. It will still take me AGES to remove asll the old mastic from the frame, but it will be done in due course.
And finally, on to the windscreen. Again, as there was no likelihood of me ever reusing the rubber (brittle, cracked and just plain nasty) I didn't call a friend. I simply ran a Stanley blade down the sides and over the top and gently pushed the screen forward. Perfect! I have put it somewhere where it can't get knocked for safekeeping. More later!
New swtiches & gauges. I will be losing the wood trim.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas232.jpg)
Side windows out - Offside...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas233.jpg)
...and Nearside
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas234.jpg)
Hinge bolts conveniently all snapped...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas235.jpg)
...allowing me to remove the hatch easily.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas236.jpg)
How the hell do I get this out??
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas237.jpg)
Screws hidden under seal and goo.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas238.jpg)
All screws out, ready to go...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas239.jpg)
...and GONE! Numerous screws visible.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas240.jpg)
Monumental pile of crap from the sunroof.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas243.jpg)
Split the rubber down the side, push the screen...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas241.jpg)
...and there it isn't.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas242.jpg)
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Good stuff dude, enjoying this thread hugely.
Nick
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Once again, neglect of my Project is something I have been suffering from over the past few weeks. However, this was not down to "Don't wanna do it anymore" syndrome. I had a big birthday bash - I turned 40, and this car was my present from Mrs Bounce - she's awesome! So, full of far too much alcohol, curry and good wishes (plus some doubtless terrifying photos to come...) it was time to crack on once more.
I had reached the stage where I couldn't really progress too much further without taking the car off its wheels; the question was: which end to start with? The car was purchased back in June last year, with previous owner Andy stating "Condition of Rear Beam is unknown". I had tapped it with a screwdriver (seemed solid enough... :shocked:) and taken a huge chance - the car had been off the road for 11 years and if the bolts on the floor were anything to go by, it was not going to be pretty.
First thing was first - I put the rear end on axle stands and set about undoing the main brake pipe to splitter union. Amazingly it undid after a hefty bit of pressure on the spanner, and a minor amount of fluid dripped on the floor. I also undid the unions on the flexi-pipes and took the splitter and pipes off entirely. The plan was to try to remove the beam and radius arms in its entirity.
Next up were the main bolts holding the beam to the heelboard. As it was just me working on the car, I had to make sure the bolts were clamped (I used Molegrips on the ones in the middle) and managed to jam a spanner on the top of each of the end bolts. The bottom end bolts were somewhat more complicated. Thankfully, one side was easy and the washer inside the car is "D" shaped, which allowed me to undo it without any issues at all. The driver's side however just turned and the only way I could get anything on the nut was to use the open-end of the spanner vertically above it; I needed to hold it there, which meant I couldn't turn the nut on the other end. Massive thanks to Mrs Bounce who had her first encounter with a ratchet spanner and coped admirably!
Next up were the nuts on top of the coilovers. Driver's side was a piece of cake. No issues at all. Other side? Hopelessly rusted solid. After several attempts to try to get them shift without any luck, I reached for the good old Dremel and cut them off. What the hell - they're being replaced anyway. I love Power Tools...
Using copious amounts of leverage with the "F" screwdriver and supporting the beam on the jack, I eased it off the car. I then removed one wheel and the coilovers and it was off. Inspection revealed it to have no more than surface rust. I am exceptionally happy about this and I actually believe it may have been replaced at some point as it appears in pretty good condition. I will strip it down, treat the rust and see what else needs reconditioning apart from the brakes. The radius arms, although rusty, are well-greased and look in fairly good order! Woo-hoo!
The beam - you're comin' off sonny!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas244.jpg)
Brake splitter - may need to be renewed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas245.jpg)
Splitter and pipe now off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas246.jpg)
Driver's side nuts no problem...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas247.jpg)
...but I had to resort to power tool violence with the other side.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas248.jpg)
Beam lowered
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas249.jpg)
Coilovers off. I have no idea what they are as they're so rusty. Maybe I'll pressure wash them to find out?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas250.jpg)
One side with minor surface rust...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas251.jpg)
...and the other. I am a happy boy!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas252.jpg)
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Good stuff now the nice job of cleaning all the parts up :smiley:
-
Ok, so it's a Bank Holiday. And once the usual family visiting was done with (Hi Mum & Dad by the way...), it was garage time once more. This meant removing the radius arms from the beam and having a closer look. It was of course, raining, but one benefit of an up-and-over garage door is that provided the wind is not blowing into the garage, it makes a really good umbrella!
First job was to remove the handbrake cables and their arms. The offside split pin offered no resistance at all, sliding neatly out and allowing me to disconnect everything really easily. The nearside of course was anything but straightforward. The split pin snapped, and everything was seized solid. A quick squirt of WD40, some judicious use of MC Hammer and everything was out. The cable appears to be in pretty good nick - I reckon previous owner Andy had already replaced it, and the nearside had been parked over or near grass as most things on that side are so corroded.
There are mounting brackets for the arms which bolt through the beam, but before I could get started on these, I needed to undo the brake hoses which bolted through some other brackets on the beam itself. Once again, offside was no problem. Nearside? Yup, seized solid. After a couple of attempts resulted in a rounded off nut, I saved time by cutting through it, despite it actually looking in fairly good condition. I have new ones anyway. I then removed the grease nipples from the radius arms, and made sure the end bolts undid. Amazingly, each and every one was a piece of cake. So, once these were finger-tight, I then undid the bolts holding the brackets to the beam, undid the inner nut on each arm and used gravity to slide them off.
I put the beam on the bench (taking timeout with a pair of Molegrips and a spanner to remove the remains of that poxy brake hose) and did a more detailed inspection. Out came the screwdriver for an MOT-tester-style prod and poke. Short of some surface rust and some remains of paint (Midas' example of rustproofing??), there was absolutley nothing wrong with it. Result! So it was out with the wire wheel to clean off most of the grime and rust, with the aim to use rust remover gel on the bits I can't get to (by the brackets) then give it a decent coat of Hammerite. I am loving this as things are starting to go well again :smiley:
Disconnecting the handbrake cable
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas253.jpg)
Cable off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas254.jpg)
1st brake hose easy...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas255.jpg)
...2nd one not. Cutters!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas256.jpg)
Nearside off...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas257.jpg)
...and Offside too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas258.jpg)
Beam on bench...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas259.jpg)
...and the other side
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas260.jpg)
During cleaning
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas261.jpg)
And this is the worst bit. Screwdriver tapping test showed it to be solid.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas262.jpg)
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As I had an hour or two to spare I thought I would strip and have a close look at the radius arms. How hard could it be??? I started with the nearside.
First up, I needed to get rid of the rubber bush and metal insert left behind on the stub axle when removing the coilover. A stanley knife dealt with the rubber part, and a soaking of WD40 followed by some swearing and severe use of a pair of molegrips eventually saw it removed and in the bin. It seemed that the rest would be plain sailing. Of course it wasn't.
Drum off? Check. Handbrake Arm removed? Check. Hub cover prised off? Check. Castellated nut removed? (which had no split pin!!) Check. Hub removed? Check. Bearing off with hub? Check...ish. Half of it was left behind on the stub. Did it want to come off? Nope. Seized solid. Due to the lack of a suitable puller, I had to think laterally or it was staying there and the backplate would not come off. Using a pair of side cutters, I snipped the cage surrounding the bearing and threw all the moving parts away. I then applied heat from a blowtorch, following this up with my trusty molegrips to try to get the thing to move. it did, just. A little more movement, then I released the molegrips and off it slid, leaving no damage to the stub axle. At least I have two new wheel bearings in the garage...
The rest of the arm was easily stripped; I am debating whether to just chop them in for a pair of exchange arms as although they seem ok and were well greased, I am unsure of their history. Plus they're a bit rusty. For the sake of £35-40 odd each, it seems a no brainer.
Arm on bench
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas263.jpg)
Remains of the bush succumbing to the power of Molegrips!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas264.jpg)
Almost completely stripped after the nightmare of the stuck bearing (no photos as I was ANGRY! :evil: )
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas265.jpg)
Bumpstop removed. Looks a bit dead. These are the hydrolastic bumpstops as denoted by their number 21A1520. Not sure what they're for as they're not in the build manual anywhere...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas266.jpg)
Knackered brake cylinder with pipe still attached. It would NOT undo. Time for the bin...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas267.jpg)
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Having stripped the first radius arm, I gave the bits a quick wash in the Parts Washer. The hub will need a new bearing but everything else (including the backplate) just needs a quick wire brush and repaint. I do need a rubber gaitor for the handbrake mechanism but that aside, it's pretty straightforward. The drums though look a bit past their best, being pitted inside and rusty as hell outside. For the price they are, new ones are going to be added to the list.
I used some of the Deox-Gel I'd bought on the rear beam. It did a fantastic job, turning most of the rust into a deep brown mush when agitated with a wire brush. Once clean, I gave one side of it a coat of smooth Hammerite. I also cleaned up and painted the radius arm bracket. After leaving it overnight, I gave the other side a coat as well. Job done for now.
Time for the other radius arm. Would it be a nightmare just like the other one? Actually no. Everything came off as planned. The bolts holding the backplate on were a nightmare, needing the breaker bar to help shift them but once loose, it was all straightforward. The brake pipe was the only casualty, being so corroded it just snapped. No loss. It will be replaced anyway. The hub and bearing came off with no problem. It seems that the other bearing had "welded" itself to the shaft on the other arm, due to the small mark on it. Must go looking for new arms...
I also finally got round to removing the seatbelts. At the time when I first stripped out the interior I couldn't figure out how to get a spanner or socket on the bolts holding them in, hence why I had left them in situ. Then I had a "Eureka" moment, to combat my previous stupidity. I simply pulled the belts out as far as they would go and put a socket on. Can't believe I was so thick... :grin:
Cleaned bits from arm #1
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas268.jpg)
Dodgy drum
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas269.jpg)
Beam covered in Deox-Gel
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas270.jpg)
Cleaned bracket
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas271.jpg)
Get the paint out!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas272.jpg)
...and the other side!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas273.jpg)
Scrap brake pipe (not that it matters...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas274.jpg)
Pipe and cylinder, which went straight into file #13
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas275.jpg)
Hub off with no trouble
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas276.jpg)
Stripped arm #2
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas277.jpg)
Belt out at last! New ones on list. These are mouldy...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas278.jpg)
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Good stuff :smiley: we had the same trouble few weeks back with radius arms :angry: :laugh:
-
Bit of a frustrating day today. I took ages doing stuff, but it actually looks like I have achieved very little. If everything I have done today hadn't been rusted to the car, it probably would've taken 3 mins, not the 3 hours I spent. That said a lot of time was spent simply tidying up the garage and just looking over the car.
Most of the time was spent removing old bolts etc. I won't bore you with the ins and outs of this as I'm sure you've got better things to do than read about me struggling for ages with rusty stuff. I have finally managed to remove one of the seatbelt stalks though; I need to drill out a rivet to make the other side easier: it is rusted solid - it's going to take a fair bit of brute force and ignorance to actually shift it.
Once I had had enough of trying to remove old bolts etc, I had a long look under the bonnet; I am aiming to remove the subframe in due course and it appears that previous owner Andy has done a fair bit of work for me already. There are polybushes everywhere (including the bottom arm pins and subframe rear mounts), but there are a few bits missing. The brake pipes are one example; a lot of it doesn't make too much sense to me. There's a pipe which leaves the top of the master cylinder, goes all the way past the shock absorber mount then doubles back on itself to the splitter. Why not just go straight to it? Then there is also a small pipe from the top of the splitter which goes up and over and stops at a male connection end. I am assuming that this is supposed to somehow then connect to the pipe which clips in at the front of the subframe - however there are no unions where the brake pipes go to the calipers. I would appreciate some assistance here as every brake system I have looked at before has been complete!
There are also two weird "stubs" sticking out from the bulkhead (not quite central) and I have absolutely NO idea what these are for. Any suggestions because I am stumped.
I also removed the chassis plate and put it in a safe place. It seems it was once on the other side of the car. Curious.
Seat belt stalk finally out. Bolt will be binned!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas280.jpg)
Polybushes showing on lower arm pins. That gold paint is gonna have to go!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas281.jpg)
WHAT the hell are these???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas279.jpg)
Curious brake pipe goes nowhere then comes back on itself. Why?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas283.jpg)
Small pipe goes into thin air.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas282.jpg)
Chassis plate removed from the right...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas284.jpg)
...but obviously used to live on the left. Can anyone clarify why?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas285.jpg)
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the amount of work a full restore takes, is unbeleiveable!
i dont think ill ever do this, but at the age of 19 everthing is possible!
long do you think this will take?
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the amount of work a full restore takes, is unbeleiveable!
i dont think ill ever do this, but at the age of 19 everthing is possible!
how long do you think this will take?
I'll just answer "Yes" to this... :grin:
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the amount of work a full restore takes, is unbeleiveable!
i dont think ill ever do this, but at the age of 19 everthing is possible!
how long do you think this will take?
I'll just answer "Yes" to this... :grin:
:grin:
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Whilst I was waiting for my new angle grinder-mounted wire brush to arrive (having killed the last one), I took the disgusting rear light lenses and the front sidelights/indicators and decided to give them a really good clean. Normally in this situation I would bung them in a dishwasher, but a) we don't have one and b) I am not 100% sure my colleagues at work would be happy with me if they found car parts in with their much-used coffee mugs. So I made myself very popular with Mrs Bounce and did the washing-up. With added bits. They have come up beautifully. Fairy Liquid: cleans your light clusters wonderfully and gives you baby soft hands... :grin:
I then turned my attention to the sunroof frame. This was covered in horrible mastic-type stuff and also the remains of whatever rubber-based seal & glue was used. Having scraped the mastic off, not much was shifting the sealant & rubber so I had to try many evil concoctions that I had in stock, eventually settling on a good soaking in WD40! It's now clear of all the gunk. I have given the lip underneath a good clean up using my old mate the Dremel with a sanding attachment. It can now wait until eveything gets refitted before I do anything else to it.
The wire brush arrived so I quickly gave the brake backplates a clean-up and also stripped the bad paint from the beam (I really wasn't happy with how I had painted it before). I then gave these a good wipe down with white spirit and sprayed them with Hammerite.
It was time for that final seatbelt stalk to come out. It was clear that no amount of trying to use spanners or sockets was going to work, so I reached into the Dremel toolbox and pulled out the "reinforced" cutting disc. I am going to have to get some more of these! They're amazing! Considering that the bolts used for seatbelts are generally high tensile, it went through without too much effort (although it still took me 5 minutes to grind the bolt head off!). With the stub of the bolt in the vice and a pair of Molegrips on the captive nut on the plate I was able to remove it. I gave both plates a good clean with the wire brush attachment and have hammerited them. They'll get a second coat soon, then I will give the threads a tap to make sure they're clean and paint-free.
I also did the same with the plates where the seatbelts themselves attached to. They were disgustingly filthy with a good deal of surface rust underneath. They are now black, courtesy of the spray can!
I also cleaned up the new suspension parts I have; a nice chap on the Mini Forum was giving away loads of stuff so I managed to blag a pair of 1.5 degree negative camber bottom arms, some adjustable tie-bars and lower arm pins. Cheers Kieran!
Dead wire brush attachment
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas293.jpg)
"Just doing the washing-up sweetie!"
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas297.jpg)
My kind of draining board
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas298.jpg)
Clean again!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas286.jpg)
Removing sunroof gunk (see middle of workbench)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas292.jpg)
Now much better on the bottom...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas288.jpg)
...and on the top
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas289.jpg)
Backplates cleaned up prior to paint
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas294.jpg)
And now sprayed along with the beam
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas295.jpg)
Dremel brutally cuts!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas296.jpg)
Seatbelt stalk spreader plates looking much healthier
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas287.jpg)
Seatbelt spreader mounts. One before, one after. Amazing what a bit of elbow grease can do (especially with power tools!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas290.jpg)
New suspension bits - free!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas291.jpg)
-
Still love reading all this thread :cool:
-
I have given up waiting for a machine shop which clearly has bigger fish to fry than my rebore, crank polish and balance (they never bothered to call back with a quote in other words...) I spoke to a very good friend of mine who builds SS100 & C-type Jag replicas for a living and he put me in touch with a very pleasant gentleman. He is very much "old school" in that he has a house in the country with a massive engineering shed in the garden where he does his work. Almost my dream house... :laugh: Having had a lovely chat to him he has taken all the engine parts and will sort what I need over the next few weeks as I told him I was in no rush.
Back in the garage though, it has been a frustrating time. Once more the ugly spectre of seized rusty bolts has raised its evil head and I spent the best part of 3 hours trying to remove 3 bolts. No, REALLY. They were three of the four bolts through the bottom of the dash that hold the brackets for the heater. What should have been a simple 5 minute job with two 7/16" spanners was at first thwarted by the fact that the top of the bolts (and washers) had rusted together to form an amorphous blob of what once was metal. And of course trying to undo the nut just turned the blobs. Because of the angle they were at, I could not get the Dremel in there to cut it off flush. So I spent WAY too long cutting little bits of the bolt heads off before eventually chiselling the rest off. Then the Dremel died. The switch has killed itself. For the price of a new switch I can almost get a new Dremel; I will probably do that then sell the old one on ebay as "Spares or Repair". I really can't be bothered to try to repair it. Plus it was starting to sound a bit rough...
I dug out the engine front plate from the spares box as I remembered it REALLY needed a clean. Several years of sitting about in a box meant it was still covered in bits of old gasket sealant, some remains of the gaskets and a large amount of surface rust. I gave it a going over first with the scraper to get the gasket & sealant off, then with the wire brush attachment to remove the rust. I also cleaned the threads for the timing cover as they were full of all sorts of crud.
Finally I spent a bit of time painting the rear beam and a few brackets with Hammerite, as well as giving the brake backplates another spray coating. Note to self: when cleaning your brush with white spirit, do not drip it on the graze on your hand. Ow... :shocked:
Poxy heater bracket bolts: 3 out, one to go... (I had already thrown the other one away!!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas299.jpg)
Beam & brackets in the process of drying.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas300.jpg)
Brake backplates after a second coat
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas302.jpg)
Engine front plate after a damn good clean
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas301.jpg)
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Uh Oh! i was just thinking that if you hadn't of had your Dremel you wouldn't have even been able to start this project!
-
After much beer, lazing around by the pool and too much food in Fuerteventura, a bank holiday beckoned and it was time to get into the Manroom again. :cool:
I had received a parcel through the post: a new Dremel. I instantly put it to good use to get rid of the 5 bolts that were still left to remove; one from the heater and 4 in the floor where the old subframe used to sit. I found out that there was an easier way to remove them rather than cutting them off: Grind away with the Dremel until the bolt gets hot, then twist it out with pliers as the fibreglass will be warmed suitably to allow it to move. Made my job a lot easier, though it did stink a bit...
I turned my attention to the rusty-looking bias valve which was fitted to the beam. It had still contained brake fluid when I removed it and a quick clean-up revealed that it was surface rust only. I have covered the unions and put it to one side to be painted in due course.
After taking the bonnet off, I noticed that it still had plenty of insulation/soundproofing/heat-proofing stuff on the underside. This was over 30 years old and was hard and brittle. It was also stuck to the bonnet with the strongest glue known to mankind. It took me the best part of a morning to remove it all, with the help of a chef's blowtorch (not as brutal as one you would get from B&Q - I don't have a heat gun) and a scraper. The glue remover that my Father-in-law supplied was evil personified but whatever it was, it got the old glue off easily when applied. I also made a point of removing the bonnet hinge pins as well as the clasp, giving them all a good clean-up in preparation for paint sometime in the future.
Turning my attention to under the bonnet, I decided I was going to cut off the strange "pins" that appeared to be badly fitted close to where the carb sits. They were off centre and didn't appear to serve any purpose. If they turned out to be important they could always be re-added and relocated. They were odd things. They were some sort of plastic outer with a metal post (bolt?) in the centre. They looked like a battery terminal but weren't. Maybe they were some sort of earthing point? I guess I will never know! I have cleaned up the area where they once were and with a small amount of work it will look factory fresh.
Still under the bonnet it time to remove the final bit of brake pipework and get started on the pedal box. After a squirt of WD40, the unions on the splitter undid easily and that was cleaned up. I have kept the pipes for reference purposes when it all goes back together. When I came to remove the pedal box, I found that it is rather badly situated and I may need to modify it slightly. The bolts are just below the main crossmember and as such have been cut about so that they will fit. Just over half a washer and an angled nut does not inspire much confidence. I wondered why it was so difficult to hang a spanner on it. I used Molegrips in the end. Amazingly everything undid nice and easily (must have been all the WD40 I had been regularly feeding it!) and I soon had the pedalbox on the bench.
It was not pretty. There was a lot of rust on it. First thing was first - I had to get it apart. So I covered it in penetrating oil and left it overnight. After a good nights' soaking in 3 in 1 I was able to get the centre pin which the pedals hang on out with a LOT of effort (hammer, molegrips, brute force). I need to give the shaft a bit of a going over with some emery cloth to make sure it doesn't get stuck again before refitting it. I have recut all the threads I can, then attacked the whole lot with the wire brush and Dremel to clean it all up. They now have a coat of paint and look an awful lot better than before!
Dremel! For only £10 more than a new switch too :)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas303.jpg)
Brake bias valve now looks healthier: saved myself £70-odd...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas304.jpg)
Bolts out. At last!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas306.jpg)
Bonnet covered in nasty soundproofing.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas305.jpg)
Midway through stripping
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas308.jpg)
All done - there was a lot.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas309.jpg)
Rusty hinge pins
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas307.jpg)
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All cleaned up
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas310.jpg)
Weird post thingy removed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas311.jpg)
...which looks like this
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas312.jpg)
Carb area cleaned up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas313.jpg)
Brake splitter now clean
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas314.jpg)
Cut about bolt holding the pedal box in place
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas315.jpg)
Pedal box out
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas316.jpg)
In bits on the bench
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas317.jpg)
Thread cleaned up - pin shaft needs work though
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas318.jpg)
All cleaned...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas319.jpg)
..and painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas320.jpg)
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Hubba Hubba Hubba :cool:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas321.jpg)
New pistons bought from Mini Spares and given to the man with the amazing shed. All the machining should be done within a couple of weeks. Very excited!
-
Decided to do some more stuff in the Manroom so dug out the clutch cover and gave it a deep clean in the parts washer. This had been fitted to the spare engine that had come with the project. The oil seal had failed on this and there was caked-on oily grime all over the inside of the cover. 20 minutes' work had removed the worst, and having left it to dry I cracked on with removing everything to check whether it was reusable. The clutch arm was stiff, but I think this is more down to not being used for a VERY long time. There was all sorts of gunge and dirt but nothing had got into the actual mechanism. A bit of penetrating oil had it all apart and I reckon the arm, plunger & release bearing are all good to go again. Success!
After this, I decided that the spare pair of axle stands had been hanging around under workbench for too long. It was time to remove the front subframe. So I started undoing the bolts on the rear mountings. I say "undo" - there were no nuts on them!! I simply pushed them through into the cabin. I also thought that loosening the hub nuts whilst the car was still on its wheels would be a good plan. The nearside one had no split pin at all and was finger tight, but I couldn't get the socket on the offside one. It had been butchered beyond all recognition, and I have no idea why. Still, a bigger socket had no issues with it, so it'll be something else from this car that goes straight in the bin.The tower bolts came out next. Nice and easy, with no need for big extension bars or WD40. Then the front mounts, again, not complicated at all, just two 1/2" spanners. I pushed the shocks off their mountings then undid the two track-rod ends.
Using the trolley jack and a nice large bit of wood, up came the car and down stayed the subframe. It sounds as easy as that, although it did take a bit of time as I was on my own and being careful! So the Midas now sits on bits of wood atop four axle stands. The suspension bits all seem to be recent and/or reconditioned but are all painted in a rather grim gold shade of Hammerite. There are yellow poly bushes in abundance (including the rear mounts), and the bottom mounts for the tower bolts are made by Deflex so should be good enough to go again. I am not so sure about the others... The shocks are garbage, and the subframe is missing the bracket for the steady bar (broken off as usual). The steering rack looks fairly new. I will have to inspect it in due course... It is very obvious where the old-style subframe used to fit. The holes in the floor need filling.
Disgusting clutch cover after a clean (it was virtually all black).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas324.jpg)
Now in bits - more cleaning required.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas325.jpg)
Butchered hub nut
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas322.jpg)
Tower bolts out
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas323.jpg)
Subframe out! My car's got no wheels on it!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas326.jpg)
Deflex bushes - they'll go again.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas327.jpg)
Good looking steering rack - doubt it's seen the road in anger. Poly rear mounts very visible on the floor.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas328.jpg)
Broken bracket. I must learn to weld...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas329.jpg)
Shocks fit for the bin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas330.jpg)
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Those front sub fame lower steady arm brackets break for a pass time :sad:
Great work so far :afro:
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I finished off cleaning up the clutch components. The arm was in pretty good nick apart from the grime on it; everything went through the parts washer until it was completely clean. I then fell over the subframe, so decided to do something about it. Without having a large mate to hand, I part lifted it with the trolley jack and then slid it on to the workbench. Usually I don't have too many issues with lifting subframes on their own, but this wasn't bare - it had everything including driveshafts and a pair of vented discs fitted, so it was a bit of a handful.
The driveshafts were the first to go - I popped off the pot joints and slid the shafts out of the subframe having pushed them throught the hubs. No problems, and aside from being a bit rusty in places they look in pretty good nick. I'll inspect the cvs at a later date and replace if necessary, but all the boots will be renewed as a matter of course.
Then I moved my attention to the hubs. And the fact I didn't have a balljoint splitter... Nevermind - nothing a few gentle clouts from MC hammer couldn't sort. At least on one side anyway. The other side was not moving at all. I resorted to the blowtorch, and eventually I used the power of gravity to get it off. It appears that the nearside top arm is seized, so that's something that will need attention. The bearings look good though.
I moved on to the bottom arms and tie-bars. There was no problem with these at all; everything came apart easily and the only bad thing about them was the strange mixture of standard and poly bushes and the fact that they were covered in that revolting gold Hammerite... The front mounts looked very used which was a bit odd - why put new bits on only half the car???
Cleaned up clutch arm. Ready for paint and it'll go again.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas331.jpg)
Subframe on bench. Bloody heavy as I found out...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas332.jpg)
Driveshafts out
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas333.jpg)
Hubs on bench. New balljoints required. And NEW PAINT PLEASE!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas334.jpg)
Bumpstops look almost new.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas335.jpg)
Knackered looking teardrop mounts
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas336.jpg)
Tiebars and bottom arms with odd bushes and more of that evil paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas337.jpg)
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This morning saw me attack the discs that came off the car. The discs themselves are Metro Turbo vented items which I doubt have ever been used on the road. However, several years of standing have left them looking rather rusty. I might have a use for the drive flanges however, so I needed to get them off. I left them soaking in penetrating oil overnight, then attacked them using a block of wood and a mallet. One disc was fine, parting company with the flange after 3 hits. The other however, was more stubborn than a Tory MP on Question Time. After a fair few minutes of clouting, it did eventually come off.
I then turned my attention to the evil paint on the suspension arms. It HAD to go. Luckily I have a tool for this and spent a busy and extremely loud morning removing all the paint. I was left with a small pile of paint dust and some shinier looking components, which I will repaint in due course.
Flanges finally off and on the bench.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas341.jpg)
That paint has GOT to go...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas342.jpg)
The right tool for the job.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas338.jpg)
Paint dust (there's more on the floor and workbench)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas340.jpg)
The stripped arms. Much improved!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas339.jpg)
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Just a quick update. Went to see my good friend this evening and in between helping him chuck an engine in his Riley Elf project, I nicked his cone compressor to get my cones out. It was all straightforward and easy. And the top arm I thought was seized has freed itself off a bit too. I haven't removed the doughnuts or top arms yet - will do that on the bench when there's a bit more time.
One side done...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas343.jpg)
...and the other.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas344.jpg)
-
Another quick update - managed to get a bit of time this afternoon so I set about removing the top arms and doughnuts. The top arms were a cinch; just undo the bolts on the plate, then the big nuts on the shaft and push it out. Both the shafts looked in pretty good nick, weren't seized and had plenty of grease on them. The only things that will need replacing are the dust covers at the ends. I am hoping I can get these separately without having to buy a full rebuild kit. I took out the nylon cups where the knuckles sit as they're being replaced anyway. They gave up without a fight as they looked brand new and were covered in copperslip.
The doughnuts were somewhat different. Although easy to remove, they look very well used with cracks in the rubber and badly painted flaking hammerite on the metal bits. This is what I don't get about this car: there's some stuff that's in fantastic condition yet other parts are rubbish: why replace the top arms and not the doughnuts if you know they're not up to scratch? Never mind - I'll do both...
To make me feel a bit better I put the pedalbox back together with plenty of copperslip on the shaft. It all went together nice and easily (as it should!). The pics don't do it justice.
I didn't take a picture but I managed to scrape of some of the surface rust on the front (very seized and dead) shocks. It looks like says "Midas" on them. If that's so they're likely to be 31 years old. I am definitely not using them! :shocked:
Nearside arm out...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas345.jpg)
...and Offside arm.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas346.jpg)
Nylon knuckle cups - out without an issue.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas349.jpg)
Rather sorry looking doughnuts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas347.jpg)
Rebuilt pedalbox - better-looking in the flesh!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas348.jpg)
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Going to stick some Hi Lo's in? :cool:
Thom
-
Going to stick some Hi Lo's in? :cool:
Thom
Oh yes! :grin: :cool:
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Been following this but never commented; good work :smiley:
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only just seen this... terrific work :afro:
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Guy, Thom, Rhyso - thanks muchly! It's good to know people appreciate what I am doing! :laugh:
Having returned from a week in the Lake District (too much food, alcohol and walks - my legs hurt like hell after the first 2 days!) it was time to set about removing what was left on the shell. I started off with the damper brackets. 4 nuts to undo each side; how difficult could it be? Driver's side was a piece of cake although a bit of a struggle due to the limited access and excess rust (as usual). Turns out the bottom 2 nuts are on captive bolts. These are in the main crossmember and are inaccesible other than through the hole where the subframe tower bolts go. Which is virtually impossible without a very weird tool which I don't have. The passenger side however, because I started it on Friday 13th, was an absolute backside of a job. 3 of the nuts came off easily, but the fourth broke its captive mounting so the whole bolt just spun. Because it is in such a stupid place there was no way I could get to it. Due to the rust I would need to replace said bolt anyway, so out came my old buddy Dremel and I cut the nut & bolt off. The build manual states that it's a special plate with captive nuts that needs to be pushed in with a screwdriver. I'll have to get creative and build a couple of new ones. The damper brackets themselves are a bit strange - they're like a Mini damper bracket but with an extra bit welded on and with extra holes. And of course they are ridiculously rusty... Wire brush time methinks...
Next up were the brackets which the front subframe mounts bolt to. These were surprisingly simple and in fairly good nick, so just a spanner and ratchet needed here. They are slightly different though - wonder if these were made up by someone who got the dimensions wrong and one had to be changed?
For the sake of undoing six bolts the steering column and rack had to go. The column needed a bit of persuasion to part company with the rack (my rubber mallet helped!) but was soon off. It doesn't appear to be in bad nick, and the splines look in good condition. The rack was a bit of a surprise though. It wasn't as healthy as I had initially thought. It was ridiculously stiff, the track rod ends were shot to bits and the gaiters were damaged and perished. Time for a new one then. At least I've got a couple of brand-new old stock track rod ends on the shelf that came with the car. The rack still has that poxy gold Hammerite on it...
Walking around the car I removed the passenger side mirror blank. This was held on by a single rusty screw, which had of course seized solid and would not turn. However, I ground a straight slot in the screw with the Dremel, then used a flat balde screwdriver to undo it. It had released itself from the fibreglass due to the heat from the grinding. I also removed the two bits of rubber at the front of the rear wheelarches using the same technique. These are very strange. They appear to be protecting the beam assembly from the road grime and salt kicked up by the wheels and have been constructed of what appears to be an old inner tube. I will see what I can create to replace them.
The throttle pedal was next. It's one of the earlier (i.e Mini Mk 1-3 ) smaller pedals, but mine has a Speedwell extension on it, which I rather like. However, because of where the pedal has been placed, the extension fouls on the wheelarch so you can't get full throttle. I am not sure whether to simply remove the extension or re-mount the pedal (the captive bolts & bracket are a bit badly made) about 5mm closer to the centre of the car. I need to consider my options!
Also, after helping a good friend with his Elf, I found myself the lucky recipient of a modified Maniflow centre-exit back-box. Which may be used in due course...
There's very little left on the shell now bar the doors (which I want to get hanging properly before I take them apart), the brake & fuel lines, the rear wiring loom and about 3 bolts/studs. Almost everything is off!!
First bracket off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas350.jpg)
Nearside bracket viewed from under the wheelarch, with stubborn nut and broken captive bolt.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas351.jpg)
And out. A couple of minor grazes from the Dremel. Time for de-rusting.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas352.jpg)
Subframe front brackets & spreader plates. These will be repainted. Note they're different...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas353.jpg)
Column out - seems in good nick - I will re-do the bushes though!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas354.jpg)
Rack not so good...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas355.jpg)
... here's why #1...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas356.jpg)
... and here's why #2
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas357.jpg)
Mirror blank off. It's ugly under there!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas358.jpg)
Odd rubber things from the back of the car
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas359.jpg)
New old stock track rod ends. Yay!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas361.jpg)
Throttle pedal. Decisions, decisions...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas362.jpg)
Modified Maniflow backbox - I may well use this!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas360.jpg)
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Having bashed into the subframe for the umpteenth time this week whilst in the garage, I thought it was about time to clean it up. As it was a nice day (what's one of those??!!) I chucked it outside on the workbench and set about it with the angle grinder. After a couple of minutes it went "pop" and proceeded to spit bits of plastic all over the place. I opened it up and more bits fell out. It didn't work any more. And it was (typically) 13 months old and I had no receipt, having thrown it out the previous month... I bought a new big yellow one (as much as funds would allow anyway)from the conveniently newly-opened local Machine Mart and it breezed through the rest of the stripping with no bother at all. I didn't take all the old paint off (no point really), just the stuff with rust near it and the nasty flaky stuff.
I have given one side of the subframe a good coat of Hammerite and will flip it over and do the other side next.
I also managed to get the handbrake cable assembly apart (had to resort to Dremel-ing off the nut which had rusted solid). This will be de-rusted, painted and reconditioned with new stainless bolts etc.
Subframe before stripping
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas364.jpg)
Angle Grinder went pop...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas365.jpg)
.. to be replaced by a big heavy duty yellow one
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas366.jpg)
Subframe stripped...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas367.jpg)
...and painted
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas368.jpg)
Handbrake assembly finally apart. Very rusty.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas369.jpg)
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Great work, you keep picking off those little bits and pieces, and before you know it, you'll be running out of things to do!
Thom
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It was time to try to get the Midas out of the garage. Normally this would have meant getting it back on its wheels, but I had a secret weapon called Shaun. He had liberated an old trolley cage from his work (due to be scrapped) and cut the handles off. This gave us a lovely flat platform and a very sturdy set of wheels. The question was how to get the bodyshell on to it. Given that the pair of us would give a few rugby forwards a good test, it really was no problem at all. One at each end and lift. It really was that light.
We lined up the trolley, lifted up the rear end and slid it under, then removed all the axle stands. We then pushed it out into the evening sunlight and lined it up so it sat on the trolley better. I swept out the garage and then we pushed it back in. Brilliant!
The Midas trolley, as modelled by Fred, next door's large Tabby.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas370.jpg)
Lining it up (Shaun posing)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas371.jpg)
Out on the drive, having been lowered into place properly.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas372.jpg)
And back in the garage. If I need it moved I just push it out of the way!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas373.jpg)
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I had a little thought about the captive bolts for the damper mounts and hated the single washer idea that Midas came up with. Instead I have used much heavier gauge metal (it was once part of the bracket that the old oil cooler was mounted to) and after some careful measuring made 2 small brackets, each with 2 holes in for the bolts. I then went round to my friend Mike's house and welded in some bolts to make them captive. Once of them isn't that great (not enough gas) but once it's in place no-one's gonna see it so I don't care! I have checked and I can (just about!) get them into place via the tower bolt holes in the crossmember.
I then realised just how disgustingly dirty the poor little car had become whilst in the garage so I pushed it out onto the driveway and gave it (and the disgusting heater pipes) a blast with my newly acquired Karcher Pressure Washer (total cost: free). It's come up relatively clean too. The pipes look a bit different - there's no dirt on them now! Once dry (ater a few days baking in the garage...) I hoovered it out. It's a bit cleaner, but not much...
I had a look at my newly machined engine bits. I will start putting it together once I get my hands on a decent camshaft (awaiting funds) and new oil pump amongst other things. In the meantime it will be safely wrapped and dry-stored.
The other door panel was finally removed (now I could actually get to the passenger side of the car) and unsurprisingly there were problems. That old chestnut of the stuck rusty screws reared its ugly head again. This time it was the window winder screw and one of the small screws holding the panel on. I was able to Dremel a slot in the small screw to get a flatblade screwdriver on it which was no problem, but the winder screw was not budging. So I drilled it out. It may take a bit of work to get the stub out, but given the state of the panel holding the winder gear in place, I might convert to electric winders if I can find something small enough to fit.
I continued to look around the car to see if there was anything else to remove; there was an exhaust hanger on the rear valance which was a bit stubborn and the interior wiring loom. This has been butchered a bit - there were strange soldered bits on it with no insulation. I am undecided whether to use this or make a new one from a Mini loom. It all depends how usable it turns out to be.
Captive bolts on brackets. These have now been painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas378.jpg)
Dirty shell
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas375.jpg)
Filthy Pipes
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas374.jpg)
Clean(er) shell...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas376.jpg)
...and pipes
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas377.jpg)
Beautiful block
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas379.jpg)
+020 pistons fitted to balanced rods
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas380.jpg)
Valves & Springs
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas381.jpg)
Big Valve Head
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas382.jpg)
Door Panel Off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas383.jpg)
Awful state of window winder panel
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas384.jpg)
Exhaust hanger finally off; this was binned...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas385.jpg)
Butchered loom. Time to replace or just repair and insulate?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas386.jpg)
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That's some good work there :afro:
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Amazing work - repair the loom :wink:
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On Thursday (which is when I usually go over to my friend Mike's to help him with his various projects) I had Mike over to see if he could help with my badly fitting doors. He has a few years' experience working in a bodyshop and I have come to the conclusion that bodyshop fitters are a resourceful lot, often able to come up with leftfield solutions dependant on the tools to hand. My problem was that the frames stuck out at the top, and from what he could see, they would not easily be rectified by internal adjustment.
No, they needed to be pushed in, but how? The solution was simple, but hopefully effective. Having seen in the bodyshop how a badly sealing Mini door frame can be gently persuaded into place by light but effective bending, we looped a ratchet strap around the whole shell. We spaced the door frames with wood and placed some more wood over the window frames. The strap has been tightened and we will see how well it responds over the weekend. It might not work, but if it does, then problem solved for very little effort! The poor little thing looks like it's wearing a dental brace...
I also took a look at the cylinder head as I realised that being a former Metro head, it didn't have the heater take-off drilled out. So out came the drill and the hoover - I made a nice hole while simultaneously hoovering up the bits so they couldn't go anywhere they shouldn't.
Doors strapped up
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas387.jpg)
Wood spacer & frame protector
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas388.jpg)
I needed this like a hole in the head...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas389.jpg)
...so I made one
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas390.jpg)
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ONly thread i will actually read and not just look at the pictures! :grin: :cool:
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Ok, other than a massive tidy-up in the garage (and getting my bike roadworthy so I can start cycling to work), I have managed to do some more stuff. I had a chat with Mike about the remains of the steady bar mount on the front subframe and how they're always breaking. We both came up with the solution of a heavy duty bit of metal bolted to the subframe. I gave him a template and he knocked up something out out decent thick steel during his lunch break - top man. However, there is a bit of an issue with clearance - it's all a bit tight in there - so rather than bolt it in I may instead further my distinctively novice welding skills next time I am over at his.
I spent a good hour cleaning up more brackets and suspension bits; it is now my sole aim in life to make sure that the awful gold Hammerite is banished from this world forever. Horrible stuff.
I also took the ratchet strap off the car to check how the tension had dealt with the protruding door frames. It had done surprisingly well - there's a lot less gap now. The doors will still need a little fettling to fit properly but it is a massive improvement.
Heavy duty steady bar bracket in the making. May be welded in place rather than bolted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas391.jpg)
Cleaned brackets & suspension parts awaiting recon and/or fresh paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas392.jpg)
Marked improvement on nearside door frame...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas393.jpg)
...and on offside too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas394.jpg)
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Haven't done that much recently (been working hard and also enjoying the nice weather); managed to find a new-old stock Allegro headlight on eBay although I have also found someone who is selling new-old stock Halogen Bedford Rascal Lights. They are the same size so I may invest in a couple of them when funds allow.
I have been thinking about the ridiculous bolts that held in the pedalbox. These had been cut and ground down to within an inch of their lives and were a nightmare to undo/remove as they sit just under the front bulkhead/crossmember. What was needed here was a plate with captive bolts. So I dug around the bits box and found a broken brake disc shield. Some, hacksawing, hammering and bit of vice work had a plate bent into shape. I took it over to Mike's and welded the bolts in place. It's not pretty, but once again no-one's going to see it so I gave it a coat of paint along with all the other bits that needed it.
I have finally got round to removing the bracket for the steering column as well. This was no fun as the bolts had been sat below a leaking windscreen for a number of years and had turned into rusty amorphous blobs. I managed to undo the nut on one whereas the other required more brutal methods, namely Molegrips and a hammer (NOT a Dremel for once!). Everything will be cleaned up and reconditioned. You'll be pleased to know I have put the bolts in the bin.
Finally the petrol tank: Having failed to find a used tank at a realistic price, I am looking to have mine repaired. I am led to believe there is a place fairly nearby who can weld tank seams, so this will be on my list of things to try first. I also removed the sender unit, as I was sure it was probably past its best. Amazingly, it wasn't as bad as I'd expected, but it was still pretty grotty, especially the electrical contacts. Time for a new one.
New-old stock Allegro headlight; a snip at £9.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas395.jpg)
First coat of paint for more suspension parts & brackets
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas396.jpg)
Steering column bracket, spacers and bolts. Now cleaned and ready to be re-used.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas397.jpg)
Pedalbox captive bolt plate - made from an old disc shield!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas398.jpg)
Sender unit removed from tank. Doesn't look pretty...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas399.jpg)
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Haven't done a massive amount recently due to being too much of a social animal amongst other things, but have managed to get a couple of things sorted. I have also been painted numerous brackets etc which is not the most interesting thing to either write about or take photos of...
The revised steady bar mount at the front of the subframe is now complete (except the paint!). Mike was able to weld up the steel template during his break at work due to the works welder having much better penetration. I don't quite know what the thickness is not having measured it, but I believe it is what ships are made of. It is also very hard. I don't have a mains drill (as I don't do much drilling!) but I went through 2 drill batteries before I had completed the 5 holes I needed...
I then was able to grind off the remains of the old bracket on the subframe (somewhat puny in comparison) and test-bolted everything up. It all fitted beautifully. It's now being painted.
The handbrake bar is not in such good shape. It is extremely bent and as a result trying to cut a new thread on it resulted in disaster. I will have to sort a new one, but then again a bit of straight circular bar with some thread on it should not be too difficult to sort.
The final job I've sorted was to scare myself. I walked around the car armed with a Sharpie pen and drew round everywhere that needs some sort of attention. My car now looks a bit like a Dalmation. Oh dear.
Old subframe steady bar mount - mid-grind.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas400.jpg)
2 drill batteries used and still not through!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas401.jpg)
Test fit and solid as a big tough metal thing. I will be replacing these bolts & nuts...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas404.jpg)
Handbrake bar. A bit more bent than I first thought.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas402.jpg)
All the dodgy bits outlined. Too many...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas403.jpg)
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Have not been out into the garage much recently due to mainly not having the parts or equipment to do stuff, nor the folding stuff either. Saving for a holiday takes too much car money! :laugh:
I have however come to the decision that the single line brake system needs upgrading. The Master Cylinder that was on the car when I bought it would have needed a full rebuild anyway so it seemed a perfect time to upgrade. I bought a "Yellow Tag" item for an 80s Mini - I had 3 Minis with this set-up (with 8.4" discs and no servo) and they all had excellent brakes.
However, a trial fitting showed up a problem: it was too tall. The new Master Cylinder stands 193mm above the bracket it sits on, and I had roughly 184mm to play with. I had to options: get a smaller Master Cylinder or find some way of making it fit. Not one to mess about, I put a small blob of grease on to its highest point and carefully shut the bonnet. This then left a mark on the "stiffening ribs" which was where it was fouling. The ribs are about 12-15mm so I marked out in chalk where I needed to cut then cracked on with the Dremel. A couple of small adjustments and some tidying up and all fitted perfectly. I will be able to finish it off properly once I get some fibreglass matting & resin. I will also sort out a front to rear proportioning valve for the bulkhead.
New Master Cylinder - needs a clean. And it doesn't fit properly...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas405.jpg)
A blob of grease showed exactly where it wouldn't fit.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas406.jpg)
Chalk: ideal for showing where you need to cut on a black background...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas407.jpg)
There's plenty of clearance now!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas408.jpg)
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I have turned my attention to the bodywork now that most of the mechanical bits are off the car. There is an alarming amount of cracking by the bumper/front panel/front wings and I have no doubts that this car has been driven into something at some point. The attempts to repair it have been rather poor, with lots of filler and the total disregard for any crack rectification.
I started with grinding out the cracks on the passenger side wing by the headlight and where the repeater used to sit. I don't like repeaters on the Midas - I think the ones that were on my car came from a Maxi or similar and were so knackered they went straight in the bin. I will probably replace them with something else small, maybe from a Fiesta or something. Suggestions welcome! Then again, I might not fit some at all... There were a large number of cracks but they have ended up making a pretty pattern. It looks like a map of a large Motorway junction now...
Then I moved to the front of the car. Initially I thought there was an enormous chunk of filler in the front but it was difficult to tell because it had been primered and/or repainted really badly. I spent a few minutes sanding it with some 60 grit, and I was greeted by some good news and some bad. There wasn't as much filler as I had expected (a lot was primer which sanded off) but there were at least two applications and not all of it was blended properly. There was a massive crack where the filler met the fibreglass - some of the fibreglass actually fell out with minimal persuasion. I have ground down the first load of cracks that I can see but I am undecided on the best way forward for the front end. Do I keep what is there and work with it? Do I grind out all the filler and start again? I will take advice and decide later.
Finally I dealt with the chunk of filler on the bulkhead - I had a bit of a prod and a poke here - it turned out it was covering a hole in the bulkhead but I am not sure why or how the hole was made. I shall be attacking this with some fresh fibreglass in the future.
Cracks in front wing - lots of 'em!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas413.jpg)
First crack ground out (still a bit to do...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas414.jpg)
Looking like a motorway junction...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas415.jpg)
Sorry looking front end
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas409.jpg)
Sanded down. Some fibreglass broke off without much help
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas410.jpg)
Close up, at least two filler applications
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas411.jpg)
Most of the cracks ground out. What to do from here?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas412.jpg)
Wad of filler on bulkhead hid this. How/why was the hole here?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas416.jpg)
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Well it's been a little while since my last update. Mrs B had an operation (she's fine - nothing to worry about) so a lot of my evenings and weekends in Novemeber were spent looking after her and the house. Plus there's also the fact that recently it has been a little bit chilly in the garage... I have however been acquiring some more bits and bobs from various forums and the good ol' bay of E. I have managed to get hold of the following: two longer track-rod ends for my Negative Camber bottom arms, an LCB (my old one has a dent in the centre pipe), a brand-new Mountney D-shaped wheel along with a secondhand boss, one of the two new rubber doughnuts I need, and in my quest to avoid any likelihood of ever using a Mini heater again, an heater unit from an MGF complete with controls (Many thanks to Rob Bell for the above). I WILL make it fit!
The front end had not got any better since I last attacked it so I thought I would have a look at the filler. I made two vetical incisions through it then attacked it with a screwdriver. Yup, off flicked great chunks of it. Whoever had "repaired" it after the crash had not done a good job at all. I don't know a great deal about bodywork, but just slathering wads of filler over cracked and broken fibreglass is NOT the way forward. I spent the next half an hour chipping of great chunks of it (some of it the size of a custard cream biscuit). I then put a sander on the Dremel and ran that over the damaged fibreglass underneath. This also revealed more cracks. All of these will be properly ground out and carefully repaired.
I am not sure what the car hit, but I can only assume it was something fairly solid and immovable, like a wall - or possibly a cathedral. There are cracks all over the front end (probably due to the impact) so it is going to take an age to clean it all up. I am determined to do it properly as I want it to look half decent! Thre may well be more updates to follow which involve a great deal of Dremel use and sanding. For that I can only apologise...
Front end hiding obvious horrors.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas419.jpg)
Two small grooves then flick out the crap with a screwdriver...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas420.jpg)
Amazingly, there was gelcoat under it all. What a bodge!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas421.jpg)
Big chunks of filler. Yuk.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas422.jpg)
I am left with this...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas423.jpg)
...and this...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas424.jpg)
Front end looks ugly right now. To paraphrase the 6 million dollar man, "We can rebuild him!"
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas425.jpg)
LCB - needs a clean up and a coat of high temp paint - only cost a tenner!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas417.jpg)
MGF heater. Am looking forward to the challenge of fitting this!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas418.jpg)
Funky "D" shaped steering wheel and boss, all for under £35...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas426.jpg)
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Back in the Manroom for yet more body horrors, I kept my attentions on the nearside front corner. Closer inspection reveals that this side has also been smacked about by something solid. Whoop-di-do. The area surrounding the sidelight/indicator recess has been made up from a selection of remaining bodywork and standard body filler, so that all needed chipping out. The hammer & screwdriver have become a useful pairing here. And yes, I did manage to make at least one hole. Where the bumper sits is a mass of badly applied lumpy fibreglass which I will eventually try to smooth off. Beneath the light recess is a nasty myriad of cracking (worse even than by the headlight area) so I am going to deliberately avoid this until I can get the car on its side - that way I can work at a decent height. It also (of course) goes under the bottom of the spoiler (as it's an early 80s car do I call it an "air-dam"?) so all of it will need to be re-done. I guess I am going to learn a fair bit about repairing fibreglass.
I spent the rest of the afternoon avoiding the front end and doing a bit of sanding; the front wing top, roof and pillar area and the heat affected bulkhead were my main targets. It's amazing what a bit of 60-grit will do to a surface to clear away the crud. The whole body will be resprayed anyway so I will of course be using finer grit then eventually wet & dry to get a better finish! I also have numerous holes and gouges to fill in so it is all going to take a while. More soon.
Full of filler & other assorted rubbish...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas427.jpg)
Close up of the "underneath the bumper" horrors
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas428.jpg)
It's a cracker! There are WAY too many of these!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas429.jpg)
Most of the filler removed. Yes, it did make a hole...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas430.jpg)
Wing top looking MUCH smoother (and clean!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas431.jpg)
Bulkhead area - looking a little better.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas432.jpg)
Roof. Still attached and looking clean. No cracks, which makes a change...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas433.jpg)
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Id be making that nose into a "Plug" taking a mould and making a brand new one, cut the old nose off, and graft in new, simpler than you think, and will last a damn sight longer than trying to repair that one!
Thom
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Looks a bit ropey to me too!
If you dont like the sound of Thom's suggestion then you could put some new layers of glassfibre on the inside, at least 2 minimum I would suggest as a lot of strength has been lost.
Personally I would bond in some plywood as well.
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Had a bit of a tidy up in the Manroom (and boy did it need it!) and due to the cold weather not being ideal for playing around with fibreglass, I thought I would have a look at the front hubs. I have two sets; one is the set covered in Gold Hammerite (yuk!) which were on the car and the others were a pair that were in the spares box and are normal disc brake hubs.
I set about removing (and binning where necessary) the balljoints. Having hammered the lock tabs back down I then had the delights of trying to undo someone else's over-exuberant work with the torque wrench. On both of the "spares" hubs, the balljoint nuts were stupidly tight. I ended up using my 1 1/2 foot bar with a 3 foot metal pole on the end of that before they would shift. Something tells me someone did them up "as hard as they could", probably using the same method as me. The gold ones were much easier; just the weight of the bar plus a gentle lever seemed to have them clear.
You've also got to love the way something allegedly so simple can turn into a nightmare that takes stupid amounts of time. The rear oil seal on both of the "spares" hubs was seemingly welded in place. It eventually took much brutality involving heat, screwdrivers, pliers and a hammer. The bearings in the spares hubs were nasty - full of grit and not actually complete in one instance. The gold hubs seemed in better condition with fresher grease but both sets of bearings were binned anyway as they're an unknown quantity. Having given both pairs a cursory wipe down I noticed that the gold hubs are a bit, well "weird". Someone has taken a grinder to the front face and hasn't done a great job. I have no idea why they've done this but I won't be using them all the same. This car still never ceases to amaze me...
Two pairs of hubs for stripping
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas434.jpg)
The poxy oil seal that took far too long to remove
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas435.jpg)
Gritty, nasty interior. Will clean up nicely after a dunk in the parts washer.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas436.jpg)
Gold hubs. There's something not quite right about them...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas437.jpg)
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You realise that the outer races are still to be removed and discarded from the hubs, they should easily tap out in the opposite direction to which they are fitted, using a small drift and hammer
Apologies if you already know this :wink:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas436.jpg)
Thom
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Not a problem Thom - I did know :wink:
It is January, and as last year, the Manroom is a VERY cold place to be. As such I have decided to bring some of the work inside, and for now that meant wiring. This is very possibly my most hated thing with any car, as I don't really understand it well enough. Guess I will be learning...
I first of all cleaned up the rear loom as it had been inside a car which had been sat for 11 years. A wipe down with some white spirit made it much nicer to handle. The exposed end near the rear lights is not partcularly pretty, mainly due to the constant ingress of water. The connectors for the rear lights are poor (not usually a problem as they're easily replaced) but it's disconcerting when you try to pull them off and it brings half the (rusty) light fitting with it. There's also some butchering where the wires themselves have been cut a few inches before the connectors, then soldered back together badly and not insulated. I have no idea why this has been done, but in due course I will be replacing all the crimped connectors with proper soldered terminals and will re-solder and/or heatshrink the butchered bits. I will also remove the yellow tape and re-tape it.
Then there was the main loom to look at. This scared me a lot, so I took it round to see my good friend Mike. He is familiar with most aspects of car electrics and said he'd be happy to sort it out as I've been helping him with his Biota project. He spent the best part of two hours on his kitchen floor removing stuff that wasn't needed and identifying what wires did what. It is of course, second nature to him as he's been working with electrics since the age of 16, but to the untrained eye (like me!), the man is an utter genius. He has carefully unravelled things once I had discarded all the wrapping, old tape & plastic binding, then bunched all the wires together in the proper order with the minimum of electrical prior to further modification when in the car. I want to have the fusebox inside the car anyway, so this will happen in due course.
He also gave me distinct instructions to sort out yet more exposed soldering in the main loom. I have duly cut out said rubbish, resoldered and applied heatshrink. At least I did once I started using different solder to the cheap garbage that was in my new soldering kit... It seems the old stuff is definitely the best. And I didn't set the smoke alarms off, which pleased Mrs Bounce!
Rear loom, just after I cleaned all the old gunge off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas438.jpg)
It holds such horrors as this...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas439.jpg)
..and this. Soldering iron's gonna get a lot of use.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas440.jpg)
The main loom. I kept pretending it wasn't there.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas441.jpg)
The Master at work.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas442.jpg)
All the junk taken out of the loom that wasn't needed. It's a lot.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas443.jpg)
Beautifully laid out and almost good to go. Modification, fusebox, new soldered terminals & wrapping to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas444.jpg)
Butchered bits were re-soldered, and heatshrink applied.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas445.jpg)
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There's not too much of interest to report as I have been stuck inside due to the horrid weather or been waiting for parts etc. We have managed to put an accessory feed into the loom along with the appropriate wiring for a manual fan switch. No pictures yet - all is more likely to be revealed once it's all finished - wiring isn't the most exciting of things to photograph. I have also removed the (almost always corroded) bullet connectors for the headlight looms. I find these give unnecessary problems so I always solder these together and apply heatshrink accordingly. Finally I've removed the nasty corroded bullet connectors on the end of the rear loom and used heatshrink where they were inexplicably soldered. No new spade connectors yet because Mr Numpty here ordered the wrong ones...
I suddenly realised I hadn't done anything with the rear light lenses after the studs snapped other than clean them, so I pulled them out of the lights box and set about cleaning them up so the M4 set screws I'd got would sit flat. I used my old friend the Dremel for this and ground everything flat with the smallest die grinder I had. I then mixed up some epoxy resin (which stinks of course) and glued them in place. To make sure everything was in the right place I slid the light fittings over the studs and kept them off the lenses using a screwdriver, just in cas they bonded themselves together.
After a couple of hours they were solid enough so I put them back where they should be on the car to avoid damage whilst I throw stuff around the garage!
Rear Lenses dug out of the box
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas447_zps0d1826aa.jpg)
Old fittings ground flat
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas446_zpsa92d7a59.jpg)
Light fitting added with screwdriver to make sure all was correctly placed & didn't stick...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas448_zps4f362e96.jpg)
..and the other side too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas449_zps3c249169.jpg)
Solid as a solid thing. I will leave it for several days to cure properly.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas450_zpsda473d90.jpg)
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Good old TR7 lenses! :cool:
Thom
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Good old TR7 lenses! :cool:
Thom
Tip of my tongue... was trying to think.
Haven't seen this project for ages.... Don't come in this section enough, really getting stuck in now mate, keep at it. Love it. :cool:
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Those outer ones look at a bit of an angle but if it works ........
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February sucks. It is either too cold outside to do anything worthwhile or something rubbish happens (whilst I like doing project stuff I do draw the line at working in temperatures of -4 degrees). Can you guess what happened this weekend???
Thought I would turn my attention to the rear hatch hinges which have been sitting in a box in various places whilst I tried to find a pillar drill. They were in the garage, then my brother's shed (he didn't have time despite having a pillar drill) then in the car whilst I went to pick up a pillar drill (which wasn't there - long story...) then back in the garage again. All four bolts in these had of course snapped off when I tried to remove them. This was most likely something to do with the bolts being steel and the hinges being aluminium. They don't tend to like each other over time. So my only option was to drill them out, hence the pillar drill - many thanks go to Paul for the loan of his.
So off I went to the hardware shop and bought some amazing (& expensive...) drill bits - bolts are notoriously evil things to drill out. I grabbed a piece of scrap steel and drilled a 6mm hole in it (the same as the bolt) so I could then use this as a template to accurately find and drill a pilot hole in the centre of the bolt. I also used chalk to mark exactly where the bolts sat as it was all the same colour. I started drilling with a 3mm bit and gradually worked my way up to 4.5mm. Once I had done this I should (in theory) be able to collapse the remains of the bolt and then re-tap.
However, this was not what happened. Having successfully drilled the bolt, I put the hinge down on top of the vice. And knocked it on the floor. It broke. So I now need a new one, preferably two. If you have a pair please get in touch.
February sucks.
Hinge with broken bolts & template
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas451_zps7468c33d.jpg)
Using chalk so I could accurately place the template.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas452_zps3d8f80d7.jpg)
Then this happens. Nuts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas453_zps9875001b.jpg)
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I really know how to rock a Friday night. Mrs Bounce was out with the girlies so I did man stuff. This meant opening a bottle of beer and getting down with the rear loom in the lounge. I had already had some help from Mike the previous evening (in between inhaling cellulose thinners and fibreglassing his Biota's underside) where we tested all the wires to make sure they were all working. One wasn't (one of the rear lights). This was because it was all corroded, black nearly all the way through. All the others were fine.
So we took the tape off that section of the loom and followed that bit of wire down to where it joined the other rear light wires and cut it off. We then replaced it with a new wire (the same colour from another loom in Mike's bits box) and soldered it in place. This was then heatshrunk and everything tested again. All that remained was for me to clean up the ends and fit new connectors where required and re-tape the loom. I even used yellow tape. Attention to detail and all that...
There's still a couple of small bits to attend to i.e connectors on the foglight & fuel sender, but they can wait until I have fully decided what I am using.
Loom on sofa (Don't tell the wife)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas454_zps39705fbc.jpg)
New wire soldered in & heatshrunk
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas455_zps7dbdff9b.jpg)
Now all tidy & almost finished.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas456_zps135ad72b.jpg)
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As I was wanting to avoid the wiring (and hatch hinges!) for a bit I started looking at the front bodywork again, now that I could go into the Manroom and not lose all feeling in my hands. I needed to have a closer look at the offside front as well as finishing off the nearside. I have avoided the very bottom of the airdam for now as it will be MUCH easier with the car on its side.
My afternoon was mainly spent using the Dremel, chasing cracks and grinding them out. I also found a bucketload more filler, most off which was unceremoniously chiselled out. It seems that whoever did the "bodywork" on this front end just used a bucketload of Plastic Padding with little regard to what it would end up looking like or how it would react. Still, once I've stripped it back, resin, fibreglass & a LOT of sanding will have it looking better before painting. It surely can't look any worse... There was one piece of gelcoat that had so many cracks on it that I ended up just cutting it out with the Dremel & throwing it away. It's pointless chasing 93 cracks in such a small piece of plastic when I may as well start with a blank canvas.
Engine bay lip, star-crack ground out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas463_zps5d11c808.jpg)
Indicator surround, looking a little... gouged.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas464_zps5f758d9a.jpg)
Full of Filler?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas465_zps31f2511a.jpg)
Not any more...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas457_zps377e4628.jpg)
More filler removed
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas458_zps11205160.jpg)
Offside is full of gloop too
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas459_zpsd6a1841d.jpg)
It appears to be a USA Freeway Intersection map
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas460_zpsa7bf8944.jpg)
This bit was rubbish...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas461_zpseb857e58.jpg)
...so I removed it.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas462_zps4c7cdee9.jpg)
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Had an unexpected afternoon in the Manroom today so made full use of it. As it was unlikely that I would be able to get the cast aluminium of the one hinge I have left to take a thread given my meagre tool set, I drilled it ready to take countersunk bolts (similar to the type that hold the rear drums in). It was then that I realised that the hinges are "handed" to match the small curve of the hatch opening. James from the Midas forum had sent me a spare and we didn't realise that they were different. Guess what I have got... That said, I don't think it is necessary to change them. A small amount of work on a grinder will make the "wrong" one fit fine, and unless you look REALLY closely I doubt anyone but the most anal will even notice.
Whilst at the bench I also took time to knock out the rings that the bearing races roll against in the hub. It's a job I have been meaning to do for ages (thanks, cold weather...) and I will shortly clean up the hubs ready for paint before sorting replacement bearings and balljoints.
I went back to the front end - the area where the bumper sits on the driver's side was a total mess. I reckon it was here that took the brunt of the impact when the car was shunted. There was so much cracking and badly replaed fibreglass I cut it all out - it saved a hell of a lot of time. Although it would be under where the bumper sat and therefore "unseen", I would rather it be solid than the dodgy mess it was. Dremel cuts! There was a large lump of fibreglass filler which fell out - this was where one of the bolts which held on the grille mesh had snapped. Horrible.
Talking of the bumpers, I haven't even looked at them since removing them 18 months ago. I grabbed the front one and spent AGES removing all the expanded foam from inside. There's plenty of star-crazing all over it just like on the body, which someone has tried to disguise using badly applied black paint. It's also been repaired (badly) at least twice. So that's another thing to add to the long list of repairs to do. I will also try to sort some "invisible" fixings rather than using a wood screw through into the bodywork as it was when I took it off...
Hinge redrilled & countersunk to take crosshead screw.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas467_zpse8af1539.jpg)
Oops! Two the same...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas468_zpsccf1081b.jpg)
Hubs now bare apart from steering arms. Time for clean-up & paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas469_zps051fe3a3.jpg)
This area was nasty and needed to be taken out of the equation...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas470_zpsc8522f16.jpg)
...so out came the chopper.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas472_zps9507b716.jpg)
This was the lump that fell out. Yuk.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas471_zpsdb9023cc.jpg)
Bumper before being attacked.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas473_zpsd3333fe9.jpg)
All the crap foam removed. It's a lot lighter.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas466_zps84b191cd.jpg)
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Well it's been a while. That's because my hands threatened to drop off anytime I went outside during most of March. So I didn't. I have spending my eBay funds (and birthday money) on stuff that I need for this project so numerous little parcels arriving in the post were gratefully received. I also went to Mini Spares to get some heavy stuff and to exchange an old steering rack for a new one.
The list is as follows:
New front wheel bearings
New balljoints
Exchange Steering Rack
Rack to body bush
Rack to U-bolt strips
Rear brake drums
Some core plugs for the block
A pair of brake discs
Handbrake levers (for the rear drums) and their gaiters
Lower arm bushes
2 TR7 fuel caps - one of which was the wrong one. Doh!
I also received a petrol tank sealing kit and a set of TR7 rear light gaskets for my birthday.
I was so fed up with grinding and sanding fibreglass (I am also helping a friend with his Biota - it's got about 5 layers of paint and makes my car look in good nick) that I decided to do some mechanical work. I spent the afternoon fitting the new front wheel bearings and shimming up the balljoints. I remembered that I always used to hate balljoints. After this afternoon... I still do. Only one of them was easy to sort. Each of the others took at least 10 minutes each!! At least the bearings were nice and straightforward. As I was on a roll I thought I would do the rear hub bearings too - the previous owner had chucked a couple of rear bearings in the spares box. Never trust someone who's selling you a project with the truth about bits. They were indeed bearings, but they were different from each other & neither was for a Mini. One was a rubbish ball-bearing race (and the grease had congealed - nasty). I don't know what it's from as the part number has ripped off the box. The other was a nice Timken kit for a Marina/Allegro/TR7. So that's something else to add to the shopping list.
I also decided to prepare the fuel tank for the sealing kit, so I have put the sender unit back in (not sure if Gaffa tape will hold up to it). Of course one of the bolts has sheared off. And one is missing. Where's my hammer???
New Discs
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas474_zpsce102879.jpg)
1st new fuel cap, showing how badly wrong I got it. Of course the two fittings are totally different...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas475_zps78e79688.jpg)
Steering Rack! (A present from Mrs Bounce xxx)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas476_zpsad08b731.jpg)
The 2nd fuel cap. This one fits.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas477_zps83e5899e.jpg)
Hubs all bearing'd and ball-jointed up (yes I will knock over the lock tabs before fitting to the car!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas478_zpsc43f1a69.jpg)
1st "Mini" rear bearing - for Allegro/TR7/Marina...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas479_zps844d2aa8.jpg)
2nd "Mini" bearing. I have no idea what it's for. Apart from the bin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas480_zps02763d6f.jpg)
Tried to get a photo of inside the tank. You can just see how horrible it is in there.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas481_zps3f462911.jpg)
Sender unit bolt snapped. Yay.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas482_zps5fbaa0e9.jpg)
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I'd recommend buying some strong hydrochloric acid.
No idea where you'd get it from and the fumes although not that great in mass are hideous fumes. One of my contracts gave me a bottle and the way it eats through rust is unreal! It will eat through aluminum if not careful though. Stuff I have is 33% Wheel acid. Basically what they clean wheels with.
Really helpful at rusty stuff and miles less chance of snapping stuff! Just rinse well after and use gloves!
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No need Josh - have the correct tank cleaning & sealing stuff from Frost - the only reason I put the sender back in is that I am not sure that gaffa tape will be up to keeping it in the tank... :laugh:
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This weekend I have mostly been playing with chemicals, removing rust and painting. A light touch of the Dremel's cutting disc was all that was needed to make the broken bolt move again, this time under the power of a flat-blade screwdriver. After a tiny bit of cleaning I could actually see the pinhole in the side of the tank so it was time to deal with it. I taped up the pinhole, fuel sender & fuel hose holes and got to work with the Marine Clean part of the petrol tank repair kit. This stuff is evil, even if you only use 2 pints of it, mixed half & half with warm water. Although they say in their instructions to "tape up any holes in the tank", Marine Clean of course is used to remove the built up gum & deposits from fuel. This includes glue on Gaffa tape. A little seepage was ok to deal with, although I did have to replace it quite regularly whenever I moved the tank around. I re-used the sender unit & gasket after the first "seepage" incident. You are advised to keep this evil concoction in there for 24 hours, regularly rotating the tank. Although I have no pictures to show what it can do (can't get my SLR inside the tank!) it is AMAZING stuff.
Whilst I was waiting for the Marine Clean to do its stuff, I realised I had only removed the bearings from one of the rear hubs. So I got on with the other one complete with all the surface rust and its nasty gummed up bearing. Some of the grease inside was black. The old bearings were quickly drifted out and binned. I cleaned the hubs up in the parts washer and gave them a coat of fresh paint as well as cleaning up the threads on the studs.
I also had a quick look at the old coilover shocks from the rear of the car. A bit of searching showed they're Spax units with the number "EF 377" stamped into them. I have no idea what this means, although couldn't find much on a quick Google search. Anyone got any ideas?
My calipers (which are just plain ugly) desperately need a refurb, being covered in bad black paint and rust. I managed to get the pistons out using a combination of a punch, hammer & molegrips - given the state of them it looks like the calipers were painted badly as there's paint on the exposed parts of the pistons. I shall deal with them later...
After 24 hours I drained the Marine Clean and got a frothy brown liquid which looked a bit like real ale. It did NOT smell like it... I then rinsed the tank 4 times and used the Prep & Ready rust remover. This went in neat and only needed to stay in for an hour or so. Bonus is, it's reusable (although not as strong the more times you use it). Given the seepage from the pinhole, its rust removing capabilities are pretty good. Once more the tank was rinsed.
Then, finally, it was time to seal the tank. The instructions suggest only doing this when the tank is completely dry, and you can only do this using either a heat gun or hairdryer. I don't have a heat gun, so I managed to convince Mrs Bounce to lend me her hairdryer. Luckily she doesn't use it too much, so I jammed it in the filler neck and left it on high for a while until every last patch of damp had been dried out. I then poured in the sealant, rotating the tank so it got a really good coverage, especially around the pinhole area. After draining it out the excess out, it has to be left for 96 hours to set properly. Thumb twiddling time!!
"Repaired" bolt on sender unit.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas489_zps23a2baaa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas489_zps23a2baaa.jpg.html)
Pinhole just visible in centre of pic
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas490_zps8463f735.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas490_zps8463f735.jpg.html)
Taped up (which didn't really work...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas491_zps8c27292c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas491_zps8c27292c.jpg.html)
Oh my. How good is this stuff??
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas483_zps47fb35cc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas483_zps47fb35cc.jpg.html)
Disgusting congealed grease in rear hub.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas484_zps86a30393.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas484_zps86a30393.jpg.html)
Cleaned ready for paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas485_zps11b02d44.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas485_zps11b02d44.jpg.html)
Painted & threads cleaned
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas492_zpsb1fb060f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas492_zpsb1fb060f.jpg.html)
Shocks were Spax, apparently... Anyone know what this number refers to?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas486_zpsb4805d53.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas486_zpsb4805d53.jpg.html)
How ugly are my calipers?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas487_zps5d508e5d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas487_zps5d508e5d.jpg.html)
Pistons aren't much better...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas498_zpsdfb8a805.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas498_zpsdfb8a805.jpg.html)
Beer anyone?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas493_zpsa1b31aea.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas493_zpsa1b31aea.jpg.html)
Rinse time!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas495_zpsf3ff79fa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas495_zpsf3ff79fa.jpg.html)
How to dry your tank completely. Thanks Mrs B!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas499_zps4d447283.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas499_zps4d447283.jpg.html)
Lovely silver zinc lining inside filler neck. Should now in theory be properly sealed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas494_zps834da11a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas494_zps834da11a.jpg.html)
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Tested the tank with water yesterday. It is leak free! :cool: :smug:
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Not much more to report this weekend (had a wedding to go to) apart from the tank has had its first coat of paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas500_zps68c01432.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas500_zps68c01432.jpg.html)
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Once able to get back into garage I have finished off the rear hubs - they now have their bearings and are sat inside my tool cupboard in a box so they don't end up with loads of crap in them... I then had a little think about what to do next. I have LOADS of bodywork to do I know, but I thought I would avoid that by checking out the front bumper instead. I am not entirely sure this was a wise thing to do as I found some evil stuff.
It's now well known that the guy who did the bodywork on the car after its smack on the front end can best be described as a bodge merchant. This bumper is no different, especially as it was the first thing that took the impact. It seems he has done his usual: chuck a load of filler in it then paint over the top. The matt black paint he'd used was thick & nasty and had cracked all over where there were cracks in the fibreglass, but the 80-grit 3M sandpaper I had made relatively short work of it. Sadly the cracks are fairly deep so I am going to have to grind them out. Whoop-di-doo.
There were also some repairs to the back, with a huge wodge of "new" fibreglass at the right front and in the middle, plus also an enormous lump on the underside of the bumper on the far left. And of course there was filler; but not as much as in the bodywork. Still enough to really annoy me though. Most of it is now out, leaving a hole the size of a 5p piece on the front right corner. Repairs will follow.
I also looked at the rear bumper, hoping to see no cracks as I don't believe the car has been rear-ended as well (thankfully). Still the same horrid black paint, but a lot less in the way of damage. I still have to scoop out the foam left in it though.
Hubs finished
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas502_zps8322ed93.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas502_zps8322ed93.jpg.html)
Cracks, cracks & more cracks. In the paint and in the fibreglass.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas503_zps85a4c7b1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas503_zps85a4c7b1.jpg.html)
Top, Middle or Bottom? Doesn't matter, it's ALL awful...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas504_zps82d16c02.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas504_zps82d16c02.jpg.html)
There's filler in here. What a surprise.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas505_zps8a839e45.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas505_zps8a839e45.jpg.html)
Here, too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas506_zpsd9602c14.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas506_zpsd9602c14.jpg.html)
Bottom left corner. A "step" of 2-3mm. Gotta love this guy's attention to detail.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas507_zps47fb9629.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas507_zps47fb9629.jpg.html)
"Repair" job in the middle
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas508_zps967d0c99.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas508_zps967d0c99.jpg.html)
Worst of the filler removed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas509_zpsef7ea37d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas509_zpsef7ea37d.jpg.html)
Rear bumper. Better than the front.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas501_zpsa71bd5eb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas501_zpsa71bd5eb.jpg.html)
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I attacked the bumpers this afternoon. I took the Dremel to the cracks on the front bumper (there were a LOT!). I am now covered in a mountain of fibreglass dust. I am eternally grateful for my "Bane" mask complete with filters that kept all that out of my lungs. Once I had finished being evil on the outside, there was a hole on one end and very thin fibreglass the other. So I cracked out the new fibreglass kit and patched those up from the inside. The outside has now been repaired with a varied mix of resin and P40. I have the lovely job of sanding to follow. It's my intention to use "hidden" captive nuts on brackets so I can use bolts on the inside of the car - a much tidier idea than the wood screws poking through the bodywork with the heads exposed on the outside of the bumper.
While the front was drying out, I scooped out the foam in the rear bumper. This took ages. And unfortunately, because the foam itself was not sealed into the bumper, it was partly damp. Yuk. The end bits where the screws went were covered with fibreglass, so these were Dremel'd off revealing a very rotten piece of wood underneath. These fell apart almost instantly as they'd been damage by the damp. Eventually it was all out so tomorrow I will have the delight of preparing them for any repairs they'll need. And getting rid of that awful matt black paint.
Nasty end of the front bumper...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas513_zps0d3a1ade.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas513_zps0d3a1ade.jpg.html)
...and the other one
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas510_zpsad9abfb0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas510_zpsad9abfb0.jpg.html)
Repairs on the inside at one end
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas511_zpsf5b9d3de.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas511_zpsf5b9d3de.jpg.html)
...and the other end.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas512_zpsb4ac267d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas512_zpsb4ac267d.jpg.html)
Wood in rear bumper. This was rotten.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas514_zpsd4fff3ca.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas514_zpsd4fff3ca.jpg.html)
All this came out. It's now in the bin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas515_zpsd0a4983a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas515_zpsd0a4983a.jpg.html)
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Sorry to bore everyone, but it's more bumpers today. I gave the front bumper a sand down after attacking it with resin & P40, but there were still a few low spots. As such I had another go and utilised the lovely bright sunshine to dry it out. This meant I could have a look at and sand down the rear bumper.
On first glance, this looked really quite good. After 5 minutes with a block and some 80 grit, less so. The horrid matt black paint hid a multitude of sins and I was left with some cracks, a couple of holes and an interesting bit of middle in the middle where the two halves had originally been joined together. So once again it was out with the resin and CSM. I reinforced where the cracks were and drizzled some resin into the holes having ground out & feathered the edges. More sanding tomorrow no doubt...
Front bumper drying in the sun
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas516_zpsadbf1789.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas516_zpsadbf1789.jpg.html)
Obvious join in the middle of the rear bumper
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas517_zpsfea9ad08.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas517_zpsfea9ad08.jpg.html)
Paint hid such niceties as this
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas518_zps5eb64a60.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas518_zps5eb64a60.jpg.html)
Resin applied
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas519_zps2ef8e425.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas519_zps2ef8e425.jpg.html)
Repairs made to one corner...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas520_zpsf875cbff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas520_zpsf875cbff.jpg.html)
...and also to the middle
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas521_zpsb973ae57.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas521_zpsb973ae57.jpg.html)
I have decided I like working with fibreglass again...
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The bumpers are almost finished. I say that, there's still a bit of sanding left to do prior to paint, but not much. The rear bumper cleaned up quite nicely and only needed the tiniest of skims of filler for the very occasional bit I had missed with the P40. Just 180 grit sanding & it should be ready for the next stage: fitting them to the car. I will need to make up some brackets first. I have taken advice and will not be filling the bumpers with foam.
The front bumper was a little more involved, mainly due to the large amount of sanding I had to do, but now I am just waiting for the final filler skim to dry before finishing it off prior to bracket fitting. I need access to a welder for this and that won't be for 4 weeks thanks to holidays!
I have also run out of fibreglass resin - I took the time to fill in the hole where the old remote style gear linkage sat. I stuffed the hole with various rags around a bottle then used a cardboard template (made from a Jaffa Cake box of course) which I covered with tape as a release agent, then laid the fibrgelass & resin over the top. It's not perfect, but it will do for now until I can finish it off. I made a start on covering the various holes in the bulkhead as well. There are so many of them (some of them terrifyingly bad) that I thought it'd be a good idea to blank off everything and start again from scratch. That will make it a lot tidier!
Rear bumper pretty much done
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas522_zps6093f5ec.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas522_zps6093f5ec.jpg.html)
Front one in progress - final skim done but not sanded
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas526_zps865d06ef.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas526_zps865d06ef.jpg.html)
Card in place ready for fibreglassing
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas523_zpsb2baf88f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas523_zpsb2baf88f.jpg.html)
Glassed in (still more to do)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas524_zpsc736a5fa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas524_zpsc736a5fa.jpg.html)
Bulkhead coming on before I ran out of resin...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas525_zps60912bde.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas525_zps60912bde.jpg.html)
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Aside from the final 180 grit sanding they'll need before primer, the bumpers are now pretty much complete and have been gently placed somewhere in the garage where I can't see them for a bit. Not much to report other than I did a bit more fibreglassing on the inside of the bulkhead, mainly so I could fill in all the holes engine side & start again. There are too many of them, most of which weren't being used. Therefore when I need to make holes, I can start with a blank canvas.
One of the previous owners has "extended" the battery tray, presumably to fit a standard Mini battery in there? Am not sure because 1) the car didn't come with a battery and 2) I don't have one to hand. They had done a poor job really - it seems they cut the end off, then extended it by a couple of inches holding the end on with some wire and a very thin layer of fibreglass. I have simply made it stronger by covering up the grot - no-one was likely to see it anyway as it will be hidden behind the dahboard so aesthetics are not important here!
Once the bulkhead fibreglassing was dry, I had a good sand down with 80 grit on the engine bay side and then hoovered out all the dust. Holes have now been filled with P40. More sanding will follow - I will probably end up with RSI at this rate!!
I still have to grind out the cracks on the airdam towards the bottom of the car. There are a LOT of them. Still, I now feel like I am starting to get somewhere.
Extended battery box mess cleaned up a bit.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas528_zpse765674d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas528_zpse765674d.jpg.html)
Covering yet more holes from the back.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas529_zpsba66feaa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas529_zpsba66feaa.jpg.html)
Nicely sanded bulkhead (well, part of it).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas530_zpsb54f7bf3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas530_zpsb54f7bf3.jpg.html)
Holes filled (sorry for poor photo)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas531_zps73c9a32e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas531_zps73c9a32e.jpg.html)
Oh goody - loads more cracks to deal with...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas527_zps47c5a061.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas527_zps47c5a061.jpg.html)
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Well, time for an update - lots of piccies so I will try & keep the writing bit short. The bulkhead is partly sanded (cheers Matt!) and is now hole-free & smooth. I've also finally got to grips with the front end and have ground out every crack I could see which includes under the front airdam. By the time I had finished I looked like I'd been a) flour-bombed and b) like I'd been snorting vast amounts of Columbian marching powder. I then re-glassed the thinning areas underneath, especially around the sidelight areas, behind the bumper corners and where the main impact was. Once the cracks had been dealt with I now had to fill them in. I managed to get 2/3 of it done before time ran out.
Mike came round and we took the doors off. The hinges are very stiff so I will bathe them in oil for a few days to free them off. I had been trying to figure out how to remove the door mirror (only the driver's side on my car) and after a bit of investigation found there was one VERY rusty screw holding it on through the door. Cue the drill and it was off. I was lucky enough to find a Renault 14 being broken on eBay and snaffled the passenger mirror from that for a knockdown price. The mirror is attached to the mounting plate by a pin which goes through a mounting lug on the mirror which is held in place by a metal disc & a hard rubber "doughnut". As I am going to be painting the mirror bodies I needed to separate them. The "new" mirror came apart with no problem; mine needed extra time with the Dremel. Nothing that and the drill couldn't deal with. He also helped me start thinking about where we are going to position the MGF heater. It's a big lump in comparison to the Mini heater; however it will be FAR more efficient. I have only ever experienced problems with the Mini system - the heater unit is ok but it can't breather properly. I intend using all the ventilation pipework from and may even doctor an MGF dashboard - they're a lot nearer in size than I expected so hopefully it'll fit nicely with a bit of modification. Time to find one for as cheap as possible...
Bolts to hold grill hammered from front end. It didn't take much...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas532_zps643b604a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas532_zps643b604a.jpg.html)
Bulkhead starting to look smoother (and less "holy")
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas533_zpsd0d1e612.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas533_zpsd0d1e612.jpg.html)
All the cracks now ground out. Piece missing was so bad I cut it out. It will be replaced soon I promise!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas534_zps17b6125f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas534_zps17b6125f.jpg.html)
Building up the weak bits behind with fresh fibreglass & resin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas535_zpse174df28.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas535_zpse174df28.jpg.html)
Full of fresh resin etc - lots of sanding and shaping to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas537_zpsac68ece6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas537_zpsac68ece6.jpg.html)
Doors gone!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas539_zps0e28af7e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas539_zps0e28af7e.jpg.html)
Hinges stiffer than rigor mortis in a corpse.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas540_zpsbd237f2a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas540_zpsbd237f2a.jpg.html)
Mirror mounting plate removed from door by drill
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas542_zpsa92d5d64.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas542_zpsa92d5d64.jpg.html)
"New" mirror for passenger side found on good ol' eBay. Easy to pull apart.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas538_zpsd8088ffa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas538_zpsd8088ffa.jpg.html)
Old mirror not so easy. Things either snapped or were rusted together.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas543_zpsc19ae0d8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas543_zpsc19ae0d8.jpg.html)
Finally apart; Lug needs drilling out (I have done this)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas544_zps3bb021c3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas544_zps3bb021c3.jpg.html)
Heater unit. It's a big bugger...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas541_zpsc2e3a5fa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas541_zpsc2e3a5fa.jpg.html)
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Good work!! Always look forward to your updates :afro:
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These last couple of weeks I have been a resourceful bloke. I got in touch with a guy on eBay who was selling his (slightly damaged) MGF dashboard for less than a tenner. Trouble was it was a long drive away in Loughborough and he didn't have the materials or time to send it. When it didn't sell he contacted me and said if I could get to St Ives in Cambridgeshire I could have it for free as his mate would bring it down. So a dodgy looking exchange was done in a pub carpark (I was the one wearing shades & looking shifty) and I chucked it in the boot. Massive thanks go to Ollie (who let me have it for nothing) & Dan (who brought it down). Cheers guys!
I got it home and (as expected) it is a mere 100mm different. Obviously I need to lose that from somewhere, but am undecided whther to cut the edges (I don't think there's quite enough to cut out from there) or to "doctor" the glove box area. Will let you all know when I have attacked it with the hacksaw, Dremel and fibreglass. I did take the time to repair the floppy bit by the hole for the CD player. Gaffa tape to hold it together then resin & chopped strand mat helped!
I got the missing bit from the front end and removed all the cracks (there were a LOT) on the bench, then taped it back in place before properly glassing it in from behind. I have used a bit more P40 on the front after sanding down the first lot. It is going to take a while and looks a bit rubbish right now but once done there should be a vast improvement of the chunks of filler in there when I first rescued the car!
Finally, whilst the fibreglass was drying I took time out to knock the CV joints off the driveshafts. One of them had knackered threads (this was the one where a previous owner had attacked the hub nut with a grinder) and the other was seized solid... How helpful. The spare one I had in the parts box turned out to be a used drum brake one so that was useless to me as well. The shopping list increases...
MGF Dash - free!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas545_zpsd825c1a1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas545_zpsd825c1a1.jpg.html)
Well it kind of fits...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas546_zpsadab7395.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas546_zpsadab7395.jpg.html)
Damaged repaired
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas547_zpsb935dc28.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas547_zpsb935dc28.jpg.html)
Missing front panel replaced.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas548_zps2ef0ffb2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas548_zps2ef0ffb2.jpg.html)
New fibreglass behind it.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas549_zps45f365c7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas549_zps45f365c7.jpg.html)
CV Joints removed from driveshafts. New ones needed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas550_zps3a5be197.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas550_zps3a5be197.jpg.html)
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I thought it was about time I pushed the car outside to give it a check over to see if I had any other bits of bodywork to do. Of course there was more to do, but thankfully nowhere near as much as the front end. I am really starting to dislike sanding. I think what I am going to have to do is get an army of mates over with a shedload of sanding blocks, some beers, chips and dips and just tell 'em to get on with it!! :grin:
What I found was some minor damage on the offside rear wheelarch which had been "repaired" (yup, just a load of filler chucked in - I dealt with this by hammer, screwdriver and anger...), some cracks by the rear number plate surround and in the thin fibreglass at the top of the door apertures. I have sanded and dealt with all of them, adding some additional fibreglass for extra strength behind the thin bits. I have now run out of resin again...
I also did some more work on the front end, but as it is such an awkward angle to work at I will get a friend to help me turn the shell onto one side before I attempt anymore. More later.
P40 used in the arch. I previously used a hammer & screwdriver to knock out huge wads of body filler. Lovely...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas551_zps6150e9e7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas551_zps6150e9e7.jpg.html)
Ground out cracks dealt with.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas552_zpsadafab05.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas552_zpsadafab05.jpg.html)
The mouse is out of the house!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas553_zps293a1e61.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas553_zps293a1e61.jpg.html)
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You love fibreglass like I do! :grin:
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that`s one hell of a project, you're a braver man than I!
keep up the good work!
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Due to multiple work and social committments I have left the little beastie in the garage for 2 weeks and haven't touched it; high time I brought it out for some work. The front end needed more sanding - I spent most of the morning concentrating on sorting out & smoothing the nose area. It's very close now - one more application then a small skim of filler and all will look good. I still have so much to concentrate on - under where the bumper sits still needs a lot of attention, but because it's close to the ground at the moment and the work around the sidelights/indicator recesses is intricate, I will leave it until the car's on its side and it's more accessible. The door apertures are practically complete. The rear numberplate area is done, the badge holes filled in and the rear wheel arch repairs are almost finished. I have also used P40 on the remaining ground out cracks around the bonnet aperture. But I still hate sanding. Hopefully not too much more to do...
I have decided where the dashboard will be modified. It's currently 120mm too wide and I have concluded that the side vents can go. It was either those or some very clever surgery on just the passenger side, and that would give me an offset centre console, not something I wanted at all. There is a separate piece that fits under the top of the dashboard which funnels air to the vents. This will need to be cut and sealed off due to there being no end vents. Saves a bit of weight I suppose! The cowling for the instruments may be slightly offset when it's finished (not by much I doubt) but given that the Mini dials couldn't be seen much either, I don't think it's going to matter too much. I have measured up where I will be cutting and also sorted the curvature of the top of the dashboard so it butts up nicely to the bottom of the windscreen. I knew there was a reason for keeping the original Midas dashtop rail!! Surgery will commence in due course.
Front end looking smoother (not that you can really tell...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas554_zps21d57baf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas554_zps21d57baf.jpg.html)
Door apertures looking healthier.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas555_zpsae56d02d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas555_zpsae56d02d.jpg.html)
Rear end better, but the foglight holes still need sorting.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas556_zps3cab34a8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas556_zps3cab34a8.jpg.html)
Dashboard taped up ready to be cut about. Unless I change my mind!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas557_zps70013f26.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas557_zps70013f26.jpg.html)
Vent "casting" in preparation for considerable shortening.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas558_zpsb4b1285b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas558_zpsb4b1285b.jpg.html)
The instrument cowling fits nicely. The shade that goes over the top is missing and they're silly money on eBay. I might make one if I can't find one cheaply.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas559_zps86654a46.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas559_zps86654a46.jpg.html)
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I found myself with a free evening plus the added likelihood of 2 friends round at the same time. As a result I thought it was time to turn the car onto its side so I could spend a bit of time "cleaning up" underneath. James & Matt came over and we first pushed the car out onto the drive on its trolley, then gently rolled it onto its side on the grass.
I clipped all the little bits of wire tying the fuel and brake lines to all the clips then removed them and stored them carefully in the garage. The fuel line can certainly be used again - I will give it a blow through and a good clean up first though. Am tempted to change all the clips as I think the ones on the the car are the originals and therefore 32 year-old brittle plastic. Trouble is there's a lot of them and that's a lot of holes to fill.
Talking of filling holes, there's plenty of that to do underneath; where the old seats used to sit, the old subframe mount holes, the old handbrake mount holes, the old gearbox mount holes and a few other random ones where I can't figure out what they were used for. I have also found a bit of damage (at the middle under the rear valance where an old bolt had rusted away) and I have already trimmed the remains of it away. In the meantime I have pressure washed & degreased the underside. Plenty more to do but all in good time...
One last thing. Am thinking of exhausts, but where to mount them. Seeing that they're heavy buggers, I had wanted to do a centre exit but may change this due to having no idea where to hang it from. Answers on a postcard please.
It's a rollover! Disgusting grease marks removed. Fuel & brake lines now removed. Holes still there...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas560_zps87b3e08d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas560_zps87b3e08d.jpg.html)
Thanks to Matt & James, it's now on the trolley. Yes, I did check clearance before putting it back in the garage...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas561_zps56503698.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas561_zps56503698.jpg.html)
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Time to take a look at the underside to see what horrors I have missed so far. There was a spider crack on the underside of the valance which has been ground out along with some cracking by the bolt holes for the handbrake. I also sorted the damage in the middle of the valance by removing the very broken gelcoat & adding a small strip of fibreglass, then P40 over the top. It was then, rather distressingly, that I turned my attention to the front end.
I can only say one thing. The person who did the "repairs" to the bodywork on this car is a total muppet (I sometimes wish that forums were not swear free zones as you might get an idea of how frustrated I am - let's just say the garage turned blue. A lot.). When I was sorting out the problems on the nose, I didn't pay particular attention to the underside of it. Should have done really. It was ALL body filler. I could have cried. And the looking closer at the under bumper area on the nearside side showed more ugly bits. And a truckload more filler. And guess what? More cracks!!
I did the only thing I could do. Out came the hammer & chisel for the filler under the nose, and the angle grinder with wire brush attachment for the under bumper bit. I also found that a bit near the indicator surround was all filler. I cut it out using the Dremel. I now need more resin and fibreglass. Now what was I thinking of? Oh yeah, that's right. Yee-haa.
Spider cracks on valance ground out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas562_zpsa1ba7de3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas562_zpsa1ba7de3.jpg.html)
Damage to rear valance halfway through being corrected.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas563_zps8b552316.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas563_zps8b552316.jpg.html)
More cracks where handbrake bolts through.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas564_zps5666b04a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas564_zps5666b04a.jpg.html)
Muppetry. I hammered it out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas565_zps1b40282b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas565_zps1b40282b.jpg.html)
Lumpy bits. Time to remove...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas566_zpsb8d7deef.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas566_zpsb8d7deef.jpg.html)
Half removed showing cracks and general ugliness. Angle grinders are useful. Although mine is now white...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas567_zpsa63c8ff1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas567_zpsa63c8ff1.jpg.html)
And the rest of it. I don't know exactly how they thought it was "fixed"...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas568_zps00447d1b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas568_zps00447d1b.jpg.html)
Piece removed. All filler - with a tiny bit of fibreglass attached...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas569_zpsfbbd94dc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas569_zpsfbbd94dc.jpg.html)
There's a hole in my car. Again...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas570_zps93eeb2f1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas570_zps93eeb2f1.jpg.html)
Starting to right the wrongs. For the umpteenth time.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas571_zpsc1a70d96.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas571_zpsc1a70d96.jpg.html)
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I have to admit to quite liking other peoples' bodges. Makes me realise that my corrective work can be nowhere near as bad. I finally got some more resin and set about laying some more fibreglass behind the nose and also over the inside of the hole I made last weekend. This was where I remembered that doing a "hot mix" of resin is where you need to use it quickly. Oops. I now have a paintbrush firmly stuck to the hardened resin still in the mixing pot. Never mind...
I had a small issue of how to make sure that the repairs to the nose were straight. I used the relatively simple option of a wooden baton with clear tape wound round it and clamped to the front end. I was able to stuff the hole with P40 and will be able to peel off the baton once it's dry, leaving a straight edge. At least that's the theory.
Whilst that was drying I thought I would have a look at the fuel line. I am going to replace the brake line anyway as I have a full set of cunifer lines which came with the project, but I thought the fuel line might be salvageable. It was quite horrid really; I couldn't quite figure out whether it was covered in badly applied paint or if it was the accumulation of 30 years of grime from both the road and from just standing around in gardens. Still, wire wool is brilliant. A bit of elbow grease and the fuel line looks in good nick again. I will need to give it a blow through and will also have to re-bend it at the front beause it just won't sit right. Not too difficult a job I guess, but I will need a pipe bender.
Newly laid fibreglass under nose...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas576_zps0afc2d2f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas576_zps0afc2d2f.jpg.html)
...and around the indicator recess.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas577_zpsb2148690.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas577_zpsb2148690.jpg.html)
Baton (covered in clear tape) clamped to the front.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas572_zps0760d290.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas572_zps0760d290.jpg.html)
P40 applied. Baton *should* peel off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas573_zps65d644f6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas573_zps65d644f6.jpg.html)
Starting to clean the fuel line. Is it paint? Or is it grime?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas574_zps171d1c13.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas574_zps171d1c13.jpg.html)
Looks nice again!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas575_zpsa2faba96.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas575_zpsa2faba96.jpg.html)
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I have been a little lax recently, enjoying the hot weather both here and abroad so no recent updates and for that I can only apologise!
With the shell up on its side I could turn my attention to the vast amount of holes through the floor. These were for the old twin-cables from the handbrake as well as the lever itself, the twin bolt subframe floor mount holes, the old seat mounting bolts and where the old remote gear selector had been mounted. Tink went inside the car and gaffa-taped over the holes whilst I used the countersink drill bit to enlarge the holes a little and give the filler something to adhere to. Then it was a simple matter of filling in the holes & sanding them flat.
Talking of sanding, I feel I am getting somewhere with the front end now. It's flattening off nicely, the tape-covered baton did its job well to straighten up the nose; soon all I will need to do is to give it a thin skim of P38 in places and we will be good for some primer. However, I noticed some more cracks (groan) on the underside of the front airdam which included one which had gone right through. I have strengthened it from behind for now and will grind it out properly in due course in order to repair it properly.
Finally I have been collecting some more parts - I have 2 CV joint kits, a pair of inner boot gaiters, and have finally splashed out on a pair of recon radius arms. Big thanks to Ted at the East Anglian Mini Centre who was happy to take my hydro/dry hybrid arms in exchange.
Holes filled in - these are in the exhaust tunnel.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas579_zps78ff775e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas579_zps78ff775e.jpg.html)
Front end smoothing off. It doesn't look great but it will after the primer!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas580_zpsefec4be1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas580_zpsefec4be1.jpg.html)
More cracks! Arrrggghhhh!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas581_zps972e70ee.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas581_zps972e70ee.jpg.html)
Recon Radius Arms. At last!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas578_zps8f4191ec.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas578_zps8f4191ec.jpg.html)
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Yet more bodywork today. Am getting to be quite a dab hand at sanding. Yay me. I still hate it though. If anyone ever wants to offer me a job at a bodyshop, it will only be as the teaboy, or the bloke who is allergic to sandpaper and never does body repairs.
I ground out and repaired the crack in the bottom of the airdam then spent the rest of the afternoon filling in bits around the bottom of the bodyshell. I also spent time sorting out the hole which I'd filled where the original selector sat. I say filled. I meant chucked a load of P40 in and left to do another day. It is now much, much smoother, and nothing like the wild terrain that had been left there before.
There was a little bit of damage where the steering rack U-bolts come through the bottom of the bulkhead. I wasn't 100% sure how to deal with it but then had a brainwave. I put some tape round some old bolts and poked them through the holes, then used P40 around them. Touch wood it looks like it'll work well. The upper bulkhead repairs have been finished off with some filler and I have also applied my first skim to the front end. It appears I have turned a corner. Woo-hoo!!
Airdam repairs complete.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas582_zps29ec4f8e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas582_zps29ec4f8e.jpg.html)
Bulkhead repairs filled (pic taken halfway through - I did finish it!!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas583_zps90d61a7f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas583_zps90d61a7f.jpg.html)
Filled hole where gear selector sits midway through tidying up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas584_zps21ff5fc6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas584_zps21ff5fc6.jpg.html)
Steering rack U-bolt repairs underway.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas585_zpsae50f697.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas585_zpsae50f697.jpg.html)
First little skim of filler!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas586_zpse83914d6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas586_zpse83914d6.jpg.html)
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Had a couple of hours spare after work so spent most of doing yet more sanding. I cleaned up the repairs I had made to the bulkhead where the rack bolts through - am quite pleased with it. It needs final smoothing but that shouldn't be too much of a chore. However, having given the car a further once over I noticed I had missed a few spider cracks in the floor (some around one of the holes for the seat belts) plus some more in the front. Out came my trusty friend Dremel and I ground them out before filling them with resin. I once again did the trick of tape round the bolt to keep the hole round. I am getting tired of repairs now. Will it ever end???
Rack mounts repaired - final smoothing needed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas587_zps183ac8d8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas587_zps183ac8d8.jpg.html)
HOW MANY MORE DAMNED CRACKS ARE THERE IN THIS THING??!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas588_zpsa2e34309.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas588_zpsa2e34309.jpg.html)
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2 steps have been made forward, which is always a good thing. Unless there's 3 steps backwards. Which in this case, there were. My wife's stepbrother has a Mini and wants to put a 1275 engine in it eventually, so bought a 1980 Allegro. In Brown. On hearing this, I went to look at it and he very kindly let me have the rad in exchange for helping him eventually fit a stage one kit to the Mini. So out came the rad (took 2 minutes) and I pilfered the expansion bottle too. I'll need to get a bracket for it as the one on the car had morphed into a huge nasty rusty blob on the inner wing. I left it there. I also took the thermostat housing & the sandwich plate as these will be more suited to the heater I am using.
However, the problem with removing the thermostat housing on a 33 year old car usually means they haven't moved in those 33 years. It took 45 minutes of bad language, brute force, double nut technique and a little ingenuity. I had to remove one of the studs at home (broken of course) as it resolutely refused to move. New studs required. I will clean up the housing & the sandwich plate in due course.
I decided to back flush the radiator so blocked off the pipe to the expansion bottle and put the hose in the outlet pipe. A bit of brown sludge came out and then it all ran clear from the inlet. And the middle of the radiator. Yup, it has a hole. I might see how much it is to recore as this one has solid looking metal end tanks as opposed to the rather fimsy plastic ones on my old rad. There's a rad specialist not far from me so we'll see how it goes.
In the meantime I have done some more sanding and finally removed the remains of the old screws which held in the headlining. Am getting depressed about the body work again...
Radiator, fan & expansion bottle, as removed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas589_zpsd8d4c1dc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas589_zpsd8d4c1dc.jpg.html)
Sandwich plate & thermostat housing. They were a struggle to remove.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas590_zps877ea64a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas590_zps877ea64a.jpg.html)
And the reason I won't be using this radiator.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas591_zps399a8f8e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas591_zps399a8f8e.jpg.html)
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Been off the site for ages and thought's I'd see how you were getting on with this... looking much better but rather you than me, I hate working with GRP to this level! :sick:
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So, having found a radiator with the water retaining capabilities of a colander, it was time to take a visit down to the local Radiator specialist. I explained my predicament and he said it would be possible to recore the Allegro rad, but it wouldn't fit my budget as it would be £150. He was right. However, as I had taken down both of my old rads to show 1) what should be in the gap and b) what was ACTUALLY there when I bought the car, he was able to immediately identify the other one as that from an A-series Metro.
He disappeard upstairs and found a new/old stock one which he said had been "up there a while". He also knocked it down from £65 to £50 provided I paid cash. I have a new rad, I have supported an idependent local business and he gets to go down the pub. Everyone's happy! I will need to re-drill at least one hole as the mounting pins are in slightly different places, and I need to figure out how to mount the electric fan as that's different too, but I am nothing if not resourceful.
I had to go shopping for a Metro expansion tank & pipes though as I only had an enormous expansion tank from some sort of Ford in the bits box that came with the car. Ebay came up trumps so now I am currently making it a bit cleaner as it's a bit gungy.
New rad. Fills the hole although mounting points & fan will need fettling.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas592_zpsd7c4ae9f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas592_zpsd7c4ae9f.jpg.html)
Expansion tank with pipes. Cleaning currently underway.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas593_zps6d7069eb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas593_zps6d7069eb.jpg.html)
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Seeing as you're a man of the law, I hope you told him to ensure he declares this "cash sale" to the tax man!!
I don't know why, but this is probably the only non dub ride I regularly look in on! Probably to do with the fact it literally is a top to bottom resto and its good to see things progress from bare metal....well, fibreglass in this case! Well done with the work you've done so far, keep em comin!
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Thanks for your kind words Sean - it's that sort of thing that keeps me going. Just so fed up of sanding right now...
As for Mr Radiator man, I genuinely don't care what he does with the money as long as I have a new rad :laugh: That said I am not entirely sure if he was joking or not... :shocked:
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High time I got back into the garage. There aren't many pics today as all I have been doing is sanding, sanding and more sanding. P40 is very hard stuff and my fingers are now bleeding. That said, I really feel I have now turned a corner. I am working on the front left hand corner of the car (as it's on its side that makes it WAY more comfortable!) and it is almost time to not sand anymore. Thank ****.
I have finally got it as smooth as I am likely to at this stage, but of course there are various pockmarks and depressions. I have finally given it its first skim of filler. Now all I need is a couple of mates and it'll be time to flip it onto the other side and do that.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas594_zpsaa3d2b5a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas594_zpsaa3d2b5a.jpg.html)
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I spent this afternoon sanding down the first skim of filler and I have to say I am quite pleased with what I have done. Because of all the ground-out and re-filled cracks the aesthetics aren't that great at the moment, but it feels smooth with no obvious raised lumps. I feel I am getting somewhere. It will of course need a bit more sorting out of a few dips and gouges but that will have to wait until I have some more filler. I also took the opportunity to finish off the underside of the nose as there were still a few lumpy parts and/or chunks missing.
Whilst I was waiting for all the filler to dry off last week, I painted the brake calipers in a rather fetching shade of blue, which should offset the orange colour I want to paint the car rather nicely. I then decided to get started on reconditioning them as well, which means new seals and pistons, which I already have. I say that; it appears I only have them for one side of the car. I guess I will have to get some more... I managed to get the pistons out quite easily and have removed the seals. They looked slightly past their best. Brake cleaner is useful stuff and has made things look a lot prettier. Once I have got some new bits I will finish them.
First skim sanded; are my bodywork woes soon to be over??
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas595_zpsd5c0f1ab.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas595_zpsd5c0f1ab.jpg.html)
Blue calipers! They look SO much nicer now!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas596_zpse16b6122.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas596_zpse16b6122.jpg.html)
Old seals. Not pretty.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas597_zpse43050ca.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas597_zpse43050ca.jpg.html)
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As I haven't been able to get the Midas turned over (too much social time being taken up!!) and I didn't have any more filler anyway, I thought it was time I actually finished off the calipers. As I only had one side of the car to do it was unlikely to take a huge amount of time, but I was being ultra careful because I had never done this job before. Turns I am quite good at this! Now all I have to do is wait for the second set of pistons and seals to arrive before I can do the other one.
I have also been adding to my useful parts list. I wanted a Minispares inlet manifold - they're well made, I've had one before and I wasn't sure about the one I had in the parts box. There was nothing wrong with it; it just looked like it could be a little smoother on the inside. Getting a Minispares one meant less work with the Dremel to smooth it out. Thanks to the Mini Forum, one was bought (new but not used) and one was sold. I also helped my good friend to go through his garage finding bits for his father-in-law's Moke project, and he has chucked me a couple of bits - a switch for turning on the fan automatically and a battery disconnect switch. Very helpful!
Completed caliper. Can I do the other one please?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas598_zpsa8ef260d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas598_zpsa8ef260d.jpg.html)
New inlet manifold
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas599_zpsba1c2712.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas599_zpsba1c2712.jpg.html)
Couple of useful bits. Cheers Mr T!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas600_zps4dae9f9d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas600_zps4dae9f9d.jpg.html)
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As I had the bits for doing the second caliper, I went back into the garage and messed it all up. For those that don't know, the top seal is held in place by a metal collar, and it is very easy to get this wrong when pressing it in. And of course I managed to do it when I had had no problems with the other 3 I'd already done. So having contributed vast amounts to the swearbox, I put some more seals on order, shut the garage door and left it for a week. New seals arrived, and I promptly did the same thing again. More swearing. I was then ultra careful with the final one and had no more issues. Calipers done! (Although they will need a further coat of paint...)
I have decided that as the temperatures have dropped and there is no heater in the garage, even with a "hot" mix it's not really worth doing any filler work, so I have turned my attention to some more mechanical things. I have got my hands on a KAD Quickshift (rescued from a friends garage for a decent price - he happened to have two! - but I couldn't get the lever's collar to engage on the extension. As I have a spare full selector anyway, I tried that one. No issues at all. Now what it needs is cleaning as it is not pretty. Parts washer is on standby...
Caliper finished! (Apart from more paint)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas601_zps53d497cc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas601_zps53d497cc.jpg.html)
KAD Quickshift acquired (Really must pay for this...!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas602_zpsf0fd63d5.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas602_zpsf0fd63d5.jpg.html)
It's a bit gungy in there...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas603_zps74a764b3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas603_zps74a764b3.jpg.html)
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Coming along nicely bud!
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Cheers Nick!! :cool:
Well, the weather has turned cold. Lovely. The amazing Mrs B has bought me a present though - I've now got a Propane heater in the garage - stick it on for 10 minutes and it's lovely & toastie in there now! I will interested to see how long the gas canister lasts as the guy at the shop was desperately trying to sell me a bigger one...
Just a short update today: The gear selector and a couple of other parts (carb bits & part of the thermostat housing) have gone through the parts washer and look much improved ready for fresh grease and reassembly. I will of course be modifying the selector as it's a standard Mini part; these need to be sleeved and extended by 16cm I believe to work properly. The car was not fitted with an engine when I got it, but the previous one fitted came with a remote box anyway, which of course was totally different.
I also gave the calipers another coat of paint and have painted only half of the radius arms as they're not the easiest things to hang up...
New heater - looks like a jet engine so definitely one for the boys!
(http://i511.photobucket.com/albums/s353/MrBounce38/20131129_203922_zpse0719b64.jpg) (http://s511.photobucket.com/user/MrBounce38/media/20131129_203922_zpse0719b64.jpg.html)
Cleaner looking selector (and other bits).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas604_zps4e7ce94c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas604_zps4e7ce94c.jpg.html)
More paint applied.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas605_zpsbe34d278.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas605_zpsbe34d278.jpg.html)
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Had another couple of hours so popped into the man room and did a little bit more painting. Have now finished painting the radius arms and the calipers so will hopefully be able to start putting stuff together soon!! I was considering building up the rear beam and the front subframe but I will need the work bench for those so I dug out the steering column.
This was not the prettiest thing in my garage. Being sat in a damp car for 11 years had made it look a bit...rusty. The outer column had a few small pock marks on it and the inner section looked like it had been in a field for a month. That said, about 15 minutes with some wet & dry soon had both looking much more usable and ready for the coat of satin black that I don't have in the garage. Nuts...
Other side of the radius arms & calipers done.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas606_zps33590943.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas606_zps33590943.jpg.html)
Column apart. Not pretty.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas607_zps4d86c1e7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas607_zps4d86c1e7.jpg.html)
Looking more like it. I do have new bushes for both ends.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas608_zps4a27e9ff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas608_zps4a27e9ff.jpg.html)
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Another quick update; not much has gone on this week: I desperately need to tidy the garage as it's in a bit of a state. Meanwhile, I managed to prime and spray the outer steering column, having rubbed it down. I masked up the ignition barrel as the shear bolts had done just that and I wasn't going to spend 3 days trying to drill them out. I also got hold of some proper 3M masking tape after the big roll I had just made me very angry; it was terrible stuff that just ripped at every given opportunity. It went straight into the bin. A bit of satin black and the column is looking nice again.
Primed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas609_zps1fd9d4d4.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas609_zps1fd9d4d4.jpg.html)
...and now black again.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas610_zps7f68fb5f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas610_zps7f68fb5f.jpg.html)
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I have started to rebuild the steering column; I say started - the top bush has been greased and put in, but of course the bottom felt bush needs to be soaked in oil before using it, and ideally it should be overnight. 45 minutes is NOT enough. For everyone saying "why don't I use a plastic bush?" I am not convinced that the older columns can use them (I have read conflicting information about this) and there was a brand new felt bush that came with the car; why spend extra when for a little bit of work you already have what you need?
As I was waiting for the bush to soak, it was time to start putting some suspension bits on the front subframe. My mate Matt came over but had conveniently forgotten to bring his cone compressor. Oops. Still, we could get the lower arm pins, lower arms & tie bars fitted. Or so we thought. One side of the car was no problem at all; However as usual, the bits on this car never cease to amaze me. We were able to bolt everything up on the offside but the nuts was no tightening up. We discovered that the lower arm pin had come apart. I have never seen this before. I don't have a welder. Have to get a new one...
And whilst going through various boxes to have a sort out, I pulled out the timing cover to put with the other engine stuff, to find it's got a hole punched through it. Merry Christmas and all that.
Bush soaking. (Stop sniggering at the back!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas612_zps83efd5ce.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas612_zps83efd5ce.jpg.html)
Nearside bolted together.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas613_zpsbbd21100.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas613_zpsbbd21100.jpg.html)
You have to be kidding me!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas614_zps7f96e3fc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas614_zps7f96e3fc.jpg.html)
Timing cover with extra ventilation. Matt thinks he's got a spare in his garage. I hope...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas615_zpscb0ddc9c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas615_zpscb0ddc9c.jpg.html)
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Another small update; I popped to the East Anglian Mini Centre and they sorted me out with a spare lower arm pin so I could finish the driver's side. A little gentle persuasion with a rubber mallet and some Copperslip so it doesn't all rust together and everything was done. Cone compressor next so the Hi-Los and doughnuts can go in along with the hubs.
I also had a wonderful struggle getting the felt bush into the steering column. It's now all together but of course I scratched the new paint so had to give it a quick blow-over. And I had forgotten to paint the bracket that goes with it. So that's now primed.
Driver's side lower pins, arms and tiebars now in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas616_zps5e262b21.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas616_zps5e262b21.jpg.html)
Oops. Didn't mean to do that... Now repainted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas617_zpsec3fba62.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas617_zpsec3fba62.jpg.html)
Bracket primed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas618_zps5c9bd85d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas618_zps5c9bd85d.jpg.html)
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Well, Christmas has been and gone, and thankfully my family & friends did listen to me! A whole host of "little but useful" bits from Mini Spares along with a new tool box and a couple of tools to go in it as well ! No excuses for not getting back out into the Manroom then...
The engine has been sitting under my workbench (all wrapped up) for long enough now, so I did my World's Strongest Man impersonation (poor, I know...) and took the block outside to get it clean and ready for paint. It was not given a chemical bath when the machining was done so I have a bit more work to do. I gave it a coating of Father-in-law Steve's special degreaser (works well on bus engines!!) then set to work with an old paintbrush and a toothbrush. Much time later once it had been hosed down, I took it back inside and used my special bracket to put it on the engine stand. Works perfectly! I then gave it a coat of blue paint (same as the radius arms and calipers).
Once the paint had dried a bit, I popped out the two core plugs on the clutch end (I say popped - I really mean struggled manly for several minutes with each one) and also managed (after a hell of a fight) to remove the 4 oil gallery plugs (2 at each end of the block). I was then able to clean the oilways, using that most useful (and elusive) tool: the wire coat hanger with a bit of rag on the end. Unsurprisingly there was a load of crap in there. Several applications later it is beautifully clean. I will of course be blasting it through with an airline on numerous occasions before any engine building commences...
Christmas prezzies!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas619_zps286a751c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas619_zps286a751c.jpg.html)
Dirty block.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas620_zpscea4844f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas620_zpscea4844f.jpg.html)
Cleaner block!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas621_zps99f01bde.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas621_zps99f01bde.jpg.html)
Beautiful blue block!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas622_zps09cbfd5e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas622_zps09cbfd5e.jpg.html)
Hmmm. This may need a bit of a clean out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas623_zps59fc934e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas623_zps59fc934e.jpg.html)
Oil gallery plugs gone.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas624_zpsb03c8987.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas624_zpsb03c8987.jpg.html)
All this was in the oilways...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas625_zps30b1e306.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas625_zps30b1e306.jpg.html)
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Nice to see that you've sorted the cracks properly and not just skimmed over them like most people would :afro:
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Thanks Wazzzer - it was seeing the bodge jobs that previous owners have "repaired" that made me want to do it properly; I have not worked with fibreglass before but I read up on what to do. I am not at the stage of making moulds and panels, so did it the easier way!!
More engine stuff today; some bits went well, others less so...
I knocked out the remaining three core plugs and used my trusty wire coathanger (with some rags) and some bottle brushes to spend the best part of 2 hours cleaning every last piece of crud out of the water jacket. The amount of "old flaky" that came out didn't surprise me, as I believe this engine to be about 27 years old and never been apart before. The state of the old core plugs certainly showed that. That said, the majority of the silt build up was around the 2 end core plugs so once that was clear the water jacket looked more than capable of working properly again.
The new core plugs were gently thumped into their new homes by means of a 7/8" socket, and once this was done I turned my attention to gapping my rings. That is I would have done, but my feeler gauges hadn't been used for 10 years or so. They were a little bit (read VERY) rusty. I got some new ones from the local Machine Mart. Then the gas for the heater ran out. Welcome to 2014...
Rusty old core plugs. Nice.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas626_zps6d4e6572.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas626_zps6d4e6572.jpg.html)
The crud that came out. Yum.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas627_zps8ed15afd.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas627_zps8ed15afd.jpg.html)
Much cleaner water jacket area with new plugs ready to go in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas628_zpsdc1ff5e7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas628_zpsdc1ff5e7.jpg.html)
Block looks prettier already. Does this count as "new bling"??
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas629_zps895a994c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas629_zps895a994c.jpg.html)
One of the reason I am not gapping my rings today...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas630_zps18d6418c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas630_zps18d6418c.jpg.html)
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I have decided that I don't like Mondays. My piston rings have now been gapped correctly. As I was midway through doing the last piston (which happened to be number 3 - just the way they came off the bench!!) and putting the second ring back on to the piston, it snapped. And of course nobody in the world wants to sell a single piston ring. Off I trotted to various engineering shops, met mostly with a shake of the head. That was until I dropped into P Seager in Ipswich. They had a set of +020" rings - whilst they weren't the correct type for my piston, the second ring was identical. Of course I had to buy the whole set, but it was significantly cheaper than ordering a new set.
I gapped this one without incident then hot-footed it out of the garage before I was tempted to set fire to it.
Mondays. Thing like this happen. You don't want this to happen. It's expensive.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas631_zpsdc1cbaf7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas631_zpsdc1cbaf7.jpg.html)
Then great people like P Seager Engineering have these kicking about in the depths of their workshops.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas632_zps58576d2b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas632_zps58576d2b.jpg.html)
Crank unwrapped. Where's the assembly paste??
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas633_zps8bdd0c01.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas633_zps8bdd0c01.jpg.html)
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I am a very happy boy. As I had all the necessary bits I thought I may as well drop the crank into the block and leave it there - it was taking up space on the bench after all. So, utilising my Christmas present (cam lube) I smeared the followers liberally and chucked them in their respective holes. I don't have my cam yet (that's coming at the end of the month hopefully) but I may as well install the followers whilst I'm messing around with the block.
Part of my recent Mini Spares delivery included the oil gallery plugs, so in these went as well, with a gentle tap from a 1/4" socket. Then it was time to turn my attention to the crank, the bearing and the main caps. Having made sure everything was scrupulously clean I blasted it through with compressed air (I don't have a compressor so I used one of those cans that IT blokes have), then used plenty of oil on the bearings and pushed them home. Adding loads of engine build lube, I then carefully lowered the crank into place. It fitted beautifully. More lube, and in went the lower thrusts (that's sounds SO wrong...), followed by the middle main cap with the other thrusts attached. Then on with the other two main caps and a shedload of lube. I tightened it up and it was a smooth as you like. I then torqued it up and double checked then crank turned fine. Beautiful!
Followers in, covered in Torco MPZ. Which is VERY messy.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas635_zpsac7130cc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas635_zpsac7130cc.jpg.html)
Oil gallery plugs in one end...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas636_zps35d1ac86.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas636_zps35d1ac86.jpg.html)
...and the other.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas637_zps8c28ddca.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas637_zps8c28ddca.jpg.html)
Bearings lubed up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas634_zpse4bcc06e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas634_zpse4bcc06e.jpg.html)
Crank in place and torqued up. 'Tis a thing of beauty.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas638_zpsc49dfaff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas638_zpsc49dfaff.jpg.html)
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Pretty much the only thread I come back on here to read. Top work fella.
I once forgot to check the anti freeze in my mini and it popped 2 core plugs. No other damage though which was lucky!
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Cheers Nick - that means a lot :cool:
Back in the Manroom again it was time to fit some pistons. Apart from one small problem. No piston ring compressor. And surprisingly, none of my Mini friends had one, except one. But he wasn't sure where it was, and he happened to be in Wales for a day. I bought one instead.
As the rods and caps were all marked, I was able to carefully clean, then oil, press in the new bearings, lube everything up and then compress the piston rings. Each piston went in with no problems at all (apart from when I tried to put the first one in the wrong way round - beginner's error!), and in what seemed like no time I had four of them smoothly in their bores. Success!
Halfway through...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas639_zpsae6a4eb6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas639_zpsae6a4eb6.jpg.html)
And 4 pistons snugly in their new home.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas640_zpsd0ed6f93.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas640_zpsd0ed6f93.jpg.html)
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As I am between jobs on the engine (waiting for funds for the cam amongst other things) I built up the rear brakes. When installing the rear cylinders I found that one of my backplates had the hole for the cylinder locating lug on the wrong side (or was it the cylinder that was wrong??). Out came the drill and a new one on the correct side suddenly appeared. Gaskets went on and then I had the fun job of getting the retaining clips on. I have NEVER been able to do this whilst the backplate was on the car (never had the special tool). However, on the bench it was a cinch. I was able to lever the ends over the cylinder before tapping it down using a socket to get the lugs into the ring. I then put in the adjusters & tappets with plenty of Copperslip. In went the shoes, the springs and the handbrake levers. I tried getting the hubs on, but because I had bought cheap bearings, when torqued up to the correct setting, the hubs would not turn at all. My bad. New ones on order from Mini Spares. I HATE having to re-do jobs.
To keep me busy I dug out the cylinder head and gave it a once over with my Father-in-law Steve's evil degreaser. This made it a fair bit cleaner. I then dried it and gave it its first coat of paint to match the block. Hopefully I will be able to start lapping in the valves soon.
Backplate with locating lug on wrong side. Drill sorted this.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas641_zpsd38f093c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas641_zpsd38f093c.jpg.html)
Lovely new brakes with lots of new parts!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas642_zpsc9679a97.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas642_zpsc9679a97.jpg.html)
Dirty head, ready for a clean.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas643_zps363c48bb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas643_zps363c48bb.jpg.html)
Not very presentable, but a LOT cleaner.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas644_zps61940acc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas644_zps61940acc.jpg.html)
First coat of paint. Looks SO much nicer!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas645_zpsd3ada752.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas645_zpsd3ada752.jpg.html)
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As I had a few hours' free it was time to get lapping. No, this doesn't mean a jaunt to the local naked ladies' dancing bar, but instead some incredibly tedious work with some grinding paste and some new valves and seats. And as I had everything else that goes with them, I also built up the head.
I have decided that I also don't like my valve spring compressor. It's got a stupidly short handle which means unless you get it at EXACTLY the right angle that it likes working at, it is virtually impossible to use properly. Still, I was eventually able to add the new stem oil seals, compress all the springs, and popped in the colletts with a dab of grease. I am glad I don't have to do that again...
My new wheel bearings arrived so I sorted those (sadly didn't get the chance to use my friend's father-in-law's 15 ton press!) and have popped them on the radius arms. The grease caps are bent and horrible though. Yet more expense...
Valve-less. That soon changed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas646_zps3394475e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas646_zps3394475e.jpg.html)
Inlets in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas647_zps0489910a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas647_zps0489910a.jpg.html)
All in and looking good...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas648_zpsf01e2196.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas648_zpsf01e2196.jpg.html)
...and from the top too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas649_zpsbed3b14d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas649_zpsbed3b14d.jpg.html)
Hub on. Now need new grease caps. Joy.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas650_zps92dab4c6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas650_zps92dab4c6.jpg.html)
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Another couple of hours in the Manroom saw Matt come round with his cone compressor - time to get swearing and fit the doughnuts, Hi-Los, knuckles & top arms. Wasn't too much of a struggle apart from not being able to find both the bolts that go into the captive nuts behind the lockplate. Have left these out for now until I have had more of a chance to look for them. I also appeared to only have one rebound buffer. I KNOW I have two in a bag somewhere... Still, they can be refitted when the car's back on its wheels.
Left side done (almost - bolt missing will be added when I find them!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas651_zps75048e43.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas651_zps75048e43.jpg.html)
And same with the right!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas652_zps752206d6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas652_zps752206d6.jpg.html)
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Well it's been a while since I last wrote anything, mainly due to me doing other non-garage related stuff. I have managed to get a couple of evenings in the Manroom though, mainly consisting of going through the numerous tupperware boxes contained engine bolts, fixtures and fittings which the previous owner had kept from the stripdown. I am not sure how useful old big and main-end bearings are (apart from for locking the flywheel), nor old valves (which looked pretty manky) but I did dig out the pushrods. They unfortunately had been kept between two pieces of gaffa tape, which was at least 5 years old. I didn't much fancy scrubbing these clean; however my friend has a wire-wheel attachment on his bench grinder, so a quick few minutes' work saw them useable again. I will give them a dunk in the parts washer too just to make sure!
I also pulled the cam out from somewhere deep under the bench. This was just a standard low compression Metro A+ unit so not much use to me; I was shocked at how much cams have gone up but this is of course because they now have to be made from new blanks. Gone are the days of buying a Kent cam kit for £60... Luckily for me, Mini Spares do their own flavours and once the £50 exchange was taken into account, £70 odd is much nicer than about £180! I have gone for their Evolution 001 (similar to the Kent 286) which they put into their built 1293 & 1380 engines. That's good enough for me. I did consider the Evolution 002 (similar to the Kent 266) but I have already had an engine with one of those; this will not be an everyday car so I can cope with something a little spikier! Now I will get to play with my new dial gauge when I time it in...
Cleaned pushrods. Gaffa tape is not good for engine internals.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas654_zps31914453.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas654_zps31914453.jpg.html)
Old cam. Worth £50 to Mini Spares. They now have it...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas653_zps5375c3fa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas653_zps5375c3fa.jpg.html)
...because I have one of these!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas655_zpse273cbf0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas655_zpse273cbf0.jpg.html)
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Well I have managed to get my hands on a timing cover, which is beautifully powder coated in red. So of course it'll need painting as red & orange will look a bit rubbish together. However, as I am fitting Duplex timing gear, I needed to modify it anyway, or the chain will catch and either wear through the cover or wear itself out very quickly, or both. I need to "relieve" a small indentation on the inside, which meant hitting it with a hammer. Everyone knows that this is the best form of engineering as it's so therapeutic. I also had to get rid of the "collar" which sits on the inside of the cover around the breather hole. I used the Dremel for this as it was far easier and slightly less brutal than the angle grinder... I gave it a decent wash in the parts washer afterwards to get rid of all the swarf.
I also needed to modify the engine front plate by countersinking two holes to accommodate the two screws supplied in the Mini Spares Duplex kit. The standard bolts foul on the timing gear otherwise and everything gets messy. I was ready to fit the cam, but the box marked "Engine & gearbox gaskets" mysteriously only had a set for a gearbox. This means I need to go shopping. Again. Whoop-di-doo.
Modified (and soon to be painted) timing cover.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas656_zpsc32bbd58.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas656_zpsc32bbd58.jpg.html)
Countersunk holes in engine front plate.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas657_zps91bbc178.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas657_zps91bbc178.jpg.html)
Cam ready to go in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas658_zps8d466394.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas658_zps8d466394.jpg.html)
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I hate woodruff keys. There - I've said it. I know they're a major part of timing in an engine but they are a pain.
I lubed up the cam and gently pushed it into place, making sure I didn't bash into anything (especially the bearings) on the way. Then out came the Blue Hylomar and I chucked on the front plate, complete with properly countersunk screw holes. I loctited the screws in place and primed then bolted in the new oil pump. All I needed to do next was to line up the two timing gear wheels using the dot to dot method (lined up with a steel rule) before dropping them onto the shafts with the chain on.
With this project it was easier said than done, mainly because the woodruff key in the camshaft would not stay put. It wasn't particularly loose, it was just that if I was ever so slightly out (we are talking fractions of a millimetre here) the key would either push back and up or back and down. I just could not get the poxy thing right. After an hour of head scratching, lining up and nearly throwing things across the garage, I took a break. A swig of Pepsi Max and a couple a Jaffa Cakes later, it went on as smoothly as the Haynes manual would say ("refitting is the reversal of removal").
Of course, I am now going to check the cam timing properly using a dial gauge so it'll be interesting to see if it needs an offset wodruff key. I can then swear a lot again because I will have to do it all again...
Cam in block.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas659_zpsffc93e3d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas659_zpsffc93e3d.jpg.html)
Front plate one (before oil pump fitted)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas660_zps2d4754eb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas660_zps2d4754eb.jpg.html)
Duplex timing gear finally on (at bloomin' last!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas661_zps440ac048.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas661_zps440ac048.jpg.html)
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Armed with a dial gauge I swept into the garage feeling confident. Despite not having used one before, they sound very much scarier than they actually are as they're pretty simple to use. I had a useful guide from Andy and additional help from Doug on the Mini Forum and very constructive and valuable it was too. Thanks guys!
I first made sure that everything was perfectly set up at TDC by measuring where the gauge changed direction when number 1 piston reached the top of its stroke. The dots on the timing gear were perfectly lined up. Excellent. Then I popped a pushrod into number 1 inlet hole and took a reading of when it was at maximum lift. This was 107 degrees on the protractor wheel, exactly what the camshaft should be timed in at according to Mini Spares. I then backed up the crank by 0.025" on the dial gauge then brought it forward to 0.005" and made a note of the protractor wheel (100.5 degrees). I then turned the crank forward once again until the gauge went to zero before changing direction again. Once it read 0.005" before zero, I checked the protractor again. This time it read 112.5 degrees. I added these two figures together then divided by 2 to see if I needed an offset woodruff key. As it was 106.5 degrees and the camshaft should be timed in at 107 degrees, I would call that pretty much bang on for my engine spec. A good morning's work!!
I also fished out the timing cover bolts which had been sitting in a box of bolts since the previous owner dismantled the engine. Oh dear. They were covered in grime and dirt. I have left them soaking in some degreaser and will give them a good clean up next time.
Top Dead Centre
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas664_zps9512e48f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas664_zps9512e48f.jpg.html)
Max lift on Number 1 inlet.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas665_zpsaeb1b30b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas665_zpsaeb1b30b.jpg.html)
Difficult sums.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas662_zpsa0919c9e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas662_zpsa0919c9e.jpg.html)
Oh my. Those bolts are dirty...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas663_zps593573e8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas663_zps593573e8.jpg.html)
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The Manroom has been in a complete state, plus there were things I needed to do before starting back on the engine. So, after cleaning the place up, I finally found the oil thrower to go on the crank. It was, like the timing cover bolts, utterly filthy, so it spent 3 days in some degreaser. It was much cleaner when I had finished with it.
The timing cover I had bought was powder coated red - not an ideal match for a blue engine block and an (eventually) orange car. So out came the wet and dry and I rubbed it down, primed it and sprayed it silver. Once dry I pushed in a new oil seal and out came the Hylomar to put the new gasket on. The oil thrower was chucked on and the timing gear was given a generous coating of engine oil. The cover has been bolted down nicely and everything looks pretty smart.
I am now having the fun task of cleaning the flywheel housing and wok. They are, of course, disgusting. I also need to clean my gearbox before sending it off the Guessworks for a refurb. I sense a weekend stinking of degreaser coming up. Women like that, right??? :laugh:
Primed timing cover.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas666_zpsb1d11f9e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas666_zpsb1d11f9e.jpg.html)
And the finished article, complete with new gasket, seal & oil thrower in place.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas667_zps2caead0e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas667_zps2caead0e.jpg.html)
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Comign on nicely bud!
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Thanks Nick!
I have been busy. The wok has been stripped down, primed and resprayed in silver. Looking clean (doubt it'll stay that way for too long...). The small problem of seating has been addressed. I was casually browsing ebay and came across a pair of Mk1 MX5 seats from a car that was being broken where the buyer hadn't written a brilliant description. The auction also ended at a fairly unusual time (tea-time on a Thursday!) so I chanced my arm and chucked in a cheeky bid - nothing ventured, nothing gained. Nobody else bid on them, so I won them for the princely sum of £20. And they're in really good nick - so much better than others I have seen for sale. It did mean a 1 1/2 hour drive but I like a roadtrip. The guy selling them was a top bloke and they were much better than expected.
I also dragged the gearbox out from under the bench and gave the outside a really good clean. 30 years of road and storage grime is not a pleasant thing to have to get rid of. Still, an hour with the degreaser and toothbrush had it looking quite a lot better than before. I also was able to confirm it had a 3.44 diff by counting the crownwheel & pinion teeth.
I bunged the water pump on as it's been kicking about in the new parts box for a while, then set to modifying the runners on one of the seats as the Midas has a flat floor with none of the humps the MX5 has. It's pretty easy - lop off the front parts of the runners and drill a hole in the flat runner to run some bolts and spacers. At the back, remove the other "bent" bit so the seats will sit nicely. However, I will need father-in-law's pillar drill for this so after hacking the fronts off, I put them to one side.
Finally I have started stripping the carb. It is going to need quite a clean. It has leaves in it...
Clean wok - you could eat your dinner off it!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas668_zps1ea8b0b4.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas668_zps1ea8b0b4.jpg.html)
£20 for these. I am a very happy boy!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas669_zps78d848d9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas669_zps78d848d9.jpg.html)
How disgusting is this??!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas670_zpse604aa1d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas670_zpse604aa1d.jpg.html)
Looks a little better now - this was 3/4 of the way through cleaning.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas671_zps327c1614.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas671_zps327c1614.jpg.html)
Waterpump in place
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas672_zpsa0ed2655.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas672_zpsa0ed2655.jpg.html)
Runners off ready to be modified. 12mm bolts - weird!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas673_zpsa02d32a1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas673_zpsa02d32a1.jpg.html)
My carb might need a clean...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas674_zpsa0b0a9ff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas674_zpsa0b0a9ff.jpg.html)
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Now those seats look familiar!
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Not a huge amount to report this week other than that I have finished the modifications to the seat runners. I managed to do this without Father-in-law's pillar drill, but it probably took an awful lot longer as a result... As per my last post, I had hacksawed the front of the runners off as they're surplus to requirements and then set about removing the "spikes" that would also get in the way. These go through the runners and are held in place by a kind of rivet. The best way to remove these is to simpy drill out the rivet, which is not quite so easy with a handheld battery drill. Still, after much swarf, I was able to drill as far as I dared then twisted the remains out using the vice.
I moved on to the back of the runners where once again there are some rivets holding in the curved mounting plates that aren't required. Again, there was much cursing and swarf, but once drilled, it was an easy job. The runners are now back on the seats; I am going to get some "top hat" spacers made up with a thread on them so they can be fitted to the bolts with no likelihood of them falling off. This will make fitting the seats an easy one-man process.
I have started to clean the carb. I have given the dashpot, spring, damper and needle their first go through the parts washer - I think I need to give them another go as they're still a bit dirty. Lovely...
Rear mount removed - just add bolts and spacers to fit!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas678_zpsbc76797d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas678_zpsbc76797d.jpg.html)
Bits removed from the runners. A weight saving if nothing else...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas675_zpsfd0e8b28.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas675_zpsfd0e8b28.jpg.html)
Runners fitted back to seats.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas676_zps7904fd2c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas676_zps7904fd2c.jpg.html)
Carb parts after their first clean - they're still dirty!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas677_zps61931843.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas677_zps61931843.jpg.html)
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I needed to turn the body over as the nearside front end needs a bucketload of sanding and sorting following all my fibreglass rectification. This meant calling Shaun again. Cheers buddy! We carefully rolled the shell outside, then whilst we had it out, we put it the right way up. The reason for this was to mark the positions on the floor for the seat runners. This was the first time I had sat in the car since buying it nearly 3 years ago! I made "Vroom!" noises, naturally.
There is not a lot of room in there, even for a relative shortarse like me (5ft 8"). The seats (although small) are only an inch and a bit away from touching the roof. We have positioned them close to the exhaust tunnel; I did consider swapping the seats around so the marginally better condition passenger seat would become the driver's seat. Not a chance. They are different on each side and simply won't fit. To clear the "humps" in the floor (where the fuel and brake lines run underneath) I will need to concoct some spacers for the runners and bolts; luckily, I know a man with access to a lathe...
Once we'd done this we flipped the shell over to the other side and pushed it back into the garage. Sanding will start again soon. I am so excited by this...
Once more out into the open.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas679_zpsdac0fc69.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas679_zpsdac0fc69.jpg.html)
Sitting in it at last... "Vroom" noises made of course!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas680_zpsbca49e6d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas680_zpsbca49e6d.jpg.html)
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I hate filler, cracks in fibreglass and other people's bodges. Yup, I am now having a closer look at the driver's side nose. And man it is not pretty. There was about half an inch of filler unde it, and the area under the bumper was mishapen, bumpy and - you've guessed it - full of yet more poxy cracks. I am annoyed at myself for missing them beforehand. Anyway, out came the powertools again. I even resorted to the angle grinder with the wire brush at one point as I just needed to get all the old crap out.
The Dremel once again came in very handy sorting out the cracks - it took me over half an hour to get all the ones I could see. However I am now on my last cutting disc, having gone through 68 of them, all whilst working on this car. There were not only cracks on the nose under where the bumper sits, but also under the "air dam" and also on the wheelarch. All have been ground and have been rectified. This will be followed by some sanding. Have we been here before???
Getting the filler from under the nose out. Yup, I was picking my car's nose (with power tools).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas681_zps96d7f50e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas681_zps96d7f50e.jpg.html)
Not the best of pictures, but look at all those "lovely" cracks.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas682_zpse73aa412.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas682_zpse73aa412.jpg.html)
Midway through getting all the garbage out of the under bumper area.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas683_zpsae47de5f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas683_zpsae47de5f.jpg.html)
Once again, surgery is required...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas684_zps683c16cb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas684_zps683c16cb.jpg.html)
And also under the wheelarch.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas685_zps809f4c55.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas685_zps809f4c55.jpg.html)
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You think you've got problems with cracked fiberglass!
(http://i45.photobucket.com/albums/f90/thom62/Mobile%20Uploads/2014-04/93412FE7-A851-413D-88CB-631526F86D8C_zpslx0f3a12.jpg) (http://s45.photobucket.com/user/thom62/media/Mobile%20Uploads/2014-04/93412FE7-A851-413D-88CB-631526F86D8C_zpslx0f3a12.jpg.html)
Seriously, keep up the good work... loving it
Thom
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Thom that's not cracked. That's f***ed!!! :laugh: :laugh: :laugh: :laugh:
My recent fun has once again involved the now filler-free (ish) nose. Lots of further grinding was required to get rid of as many cracks as possible. I will never manage it completely, but hopefully most of the problems have now been eliminated. I have repaired the underside of the nose and under the bumper, but this is the first "rough" repair, so more will doubtless be required. However, I want to use an absolute minimum of filler and although the majority of the work is under where the bumper sits, I want it done properly. I wouldn't be happy if I bought the car and saw a bodge job underneath!
I have bought a Mini centre speedo, as although I was toying with the idea of a digital unit, none of the ones on the market within my budget really appealed. I shall be going with good old analogue for now, as it only cost £6. I have taken the speedo apart to give it a good clean, and also to paint the casing as it had gone a bit rusty. A few minutes with some sandpaper and some silver spray and it looks good again. I have zeroed the mileometer and am in the process of cleaning everything. I am in two minds whether to paint the speedo needle the same orange as the car will eventually be. Not sure yet.
Finally my hunt for a new centre cap for my Mistral alloy wheels is over. My friend's father in law has made me 2 copies, one in white metal and the other in some sort of resin. The resin one is amazing; the white metal one almost as good but MUCH heavier. They'll both look good when painted. Bottle of wine coming your way sir!
Is this what called "getting a nose-job"?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas686_zps3a37c4e7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas686_zps3a37c4e7.jpg.html)
Centre Speedo - exploded view. You can see the repainted casing top left of the pic.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas687_zps03568c40.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas687_zps03568c40.jpg.html)
I have stripped it almost fully. I love intricate bits.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas688_zps2f8a82de.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas688_zps2f8a82de.jpg.html)
Wonderful "new" centre caps. Original on left, resin in middle, white metal on right.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas689_zpseedd47c0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas689_zpseedd47c0.jpg.html)
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I am almost in the process of jumping around like a crazy thing. I have reached the stage where all the nose of the car needs now is a final skim of filler and some minor tidying. Big thanks go to Shaun who gave up his Bank Holiday afternoon to watch me swearing about fibreglass. I also managed to build up the area around where the steering rack meets the body. It looked like it had worn away over the years so I have rectified this. I had a discussion with Shaun and we have both agreed that as it's not a concours car we're going to paint the underside with some sort of underseal/underbody protection paint. I know it's not factory but it will be virtually impossible for me to paint the underside in bodycolour, so I would much rather do it as a "fit and forget" method and then the car can be back on its wheels.
As I was fed up with sanding, I thought I would bung the head on the engine (the gearbox is currently with Guessworks being refreshed). It was at this point that I remembered one of the main reasons that buying an unfinished project can be a pain in the rear end. You know the engine that was dismantled into its component parts? Well... not all of the parts were there. Luckily they weren't that expensive (the four rocker studs) but it was still annoying. The rockers and all studs and nuts were given a clean up in the parts washer and then all the threads were cleaned up. I used the "two-nut" method to put the studs in the block then popped on the Payen gasket followed by the head itself. In went the pushrods and then the rocker gear. A tighten up in sequence with the torque wrench and all was done.
Final skim to do. Good.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas690_zpsb8839631.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas690_zpsb8839631.jpg.html)
Built up area around the steering rack hole (still some to do when pic was taken).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas691_zps49378d3d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas691_zps49378d3d.jpg.html)
Cleaned pushrods, studs and nuts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas692_zpsd8c16b14.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas692_zpsd8c16b14.jpg.html)
Studs in block
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas693_zps39532ca0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas693_zps39532ca0.jpg.html)
All finished and torqued down.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas694_zps32641462.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas694_zps32641462.jpg.html)
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I figured that as the head was now back on the engine along with the rockers, I may as well adjust the valve clearances. After an initial aborted attempt where I was so tired I saw fit to forget all logic, I used the "rule of 9" to sort them out their proper tolerances.
I then popped to to the London to Brighton Mini run to get my hands on some bits that I needed, which included the following:
Thermostat & 2 x gaskets
Solid front subframe rear & tower mounts (I already have the teardrops)
Rocker gasket
New washers/grommets/spacers for the rocker cover
Clutch oil seal & plastic protector
New oil filler cap
Blanking plates for both the fuel pump and heater tap
I also picked up an MG Metro rocker cover from Ted at the East Anglian Mini Centre for a tenner. Granted it's a bit grotty, but all it needs is a clean and polish. If it's too pitted, then I can easily paint it.
Talking of painting, I have also sprayed up the thermostat housing and sandwich plate along with various clutch arm parts; these are next on my list to put together.
Pile of new purchases. Rocker Cover was a particular bargain.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas696_zps19f6b724.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas696_zps19f6b724.jpg.html)
Blanking plates on and rockers adjusted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas697_zps6666d42c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas697_zps6666d42c.jpg.html)
Thermostat housing and sandwich plate in primer...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas695_zps7169291b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas695_zps7169291b.jpg.html)
...and clutch arm too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas698_zpsb2df9d68.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas698_zpsb2df9d68.jpg.html)
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I have discovered two things I could do with in the garage. One is a bigger vice; the other is a hydraulic press. I have no idea where I would put it but it would make my life a whole lot easier...
First job was to mask and spray the flywheel housing. I spent ages cleaning it then carefully masked it all off. Two coats of primer followed by a couple of coats of silver were enough to see it looking somewhat more refreshed. However, next door's barbecue was a bit of a distraction.
Next up it was clutch release bearing time. I had a brand new bearing and a brand new plunger. However, they did not fit in the vice. I decided I would use one of my sturdy G clamps (held in the vice) and started to wind the clamp in. All worked fine for a bit until it suddenly got a little easier. This is always worrying. Sure enough, the clamp had given way and cracked. Time to find someone with a press methinks...
Flywheel housing primed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas699_zps8ac43666.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas699_zps8ac43666.jpg.html)
...and painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas700_zps41d64d35.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas700_zps41d64d35.jpg.html)
One of the disadvantages of not having a press...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas701_zps4035bcdb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas701_zps4035bcdb.jpg.html)
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The clutch cover assembly is now finished. I went round to see my friend Mike and used his unfeasibly large vice (along with a socket and a nut) to properly press home the bearing onto the plunger. It took a lot of effort; I was tempted to ask Dave if could use his press. No need in the end and all looks good. Then it was just a matter of assembly, making sure the bits that usually seize were given a decent coating of Copperslip. It'll be properly adjusted once everything is on the car. I also shortened a couple of bolts so the timing-mark cover could be bolted on.
It was then time to give the underside of the body its first coat of stonechip. I spent ages masking up the bottom of the car and making sure that any holes/apertures were suitably plugged. Note: it is not the best idea to do this in bright sunshine with a hangover... Once I was happy with everything I gave a good coat of stonechip to the floorpan and the bottom half of the underbonnet area. Typically the two cans I thought would be ample ran out just before I'd finished... I left it to bake in the sun then popped it back into the garage to await the next delivery of stonechip.
Clutch cover all new and ready to go.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas702_zps50a11bee.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas702_zps50a11bee.jpg.html)
Everything masked up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas703_zps84394fa3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas703_zps84394fa3.jpg.html)
Stonechip on. Irritatingly there wasn't quite enough...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas704_zps91cafa55.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas704_zps91cafa55.jpg.html)
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This is my favourite build thread, I can't wait to see the finished product but then I will also be sad that I have no more Monday morning content to read! :grin:
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This is my favourite build thread, I can't wait to see the finished product but then I will also be sad that I have no more Monday morning content to read! :grin:
+1 on that. I have a soft spot for (proper) Minis having spent a lot of my youth driving and fixing them. My soft spot seems to have extended to Zippy.
MrBounce - some real progress is being made here and I hope your motivation is being bolstered by that. I would hate this thread to peter out before the car is finished.
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Gentlemen thank you - it is exactly these comments that motivate me further! It means a lot that people are interested in my strange plastic car and my attempts to bring it back to life. It WILL be finished!!
Not much to report this week - I moved the car out of the garage into the blazing sunshine again and finished off all the missed bits of stonechipping. I didn't take any pictures as it looks much the same as the first one. I will get a friend or two over and we'll put it back on its belly so we can start prepping it for the painting process. Eek.
I dragged the MIG welder I've been given out and decided to create my own captive nut engine mounts as the ones I had were - for want of a better word - rubbish. I ground off the crimped in round threaded "things" (they certainly weren't nuts) and cleaned up four nuts I had in the box. I then proceeded to not make a pig's ear of things and surprised myself by welding on the nuts without too much bother - I have only welded once before! I am sure it would have been better if I had a proper arc-sensitive flip-down mask rather than the hand-held one I have and things would doubtless have improved with a lot more practice, but I was quite pleased with my attempts. I wasn't the most accurate as my free hand was holding that damned mask but I know a friend with a proper mask if necessary. Granted there was a bit of pigeon-poo splatter on my first attempt (the nuts weren't spotless) and I managed to weld the tip up, but I fitted a replacement and all was good!
Captive nuts done (this is probably the best of them)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas705_zpsd9c5aff7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas705_zpsd9c5aff7.jpg.html)
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Once more I have been putting off sanding the bodywork (mainly for silly reasons such as next door having an afternoon in the garden and Mrs B telling me not to sand whilst the washing is out...) That said, the first 50% of sanding the main part of the bodyshell is now done. It makes such a difference as well. I have my mojo back and all is good. I have however got sunburn. Ow.
Before I finally got out to do some bodywork, I asked David if he would mind sandblasting my rocker cover when he next had a moment? Half an hour later, it was done! This happened when he popped back to his to get his slide hammer whilst Tink & I were trying to remove my idler bearing in my flywheel housing. We'd managed it by the time David returned, but he'd taken a while because he sandblasted the cover. Once home, I primed it then gave it two further coats of Rover Platinum Silver to go with the rest of the bits on the engine. Typically the bolts I had were too short to fit it. I rectified this with a pair of T-bars from Mini Spares, then topped it off with a new oil cap. Am tempted to have a "Midas" sticker made up for it but am not sure...
I was also struggling with my indicator stalk and after a particularly bad time in the garage I said "Sod it!" and ordered a new one from Mini Spares. This arrived and has been paired up with the good wiper stalk I have. The wiring has been recovered in decent electrical tape. Another thing I have finished was the front brake pipe on the subframe. I fitted the front braided hoses with new nuts and washers, then bent the pipe to fit as best as I could , being a total novice at this!! Although it's far from perfect, it isn't bad for a first effort and nobody's going to see it anyway unless they're really nosey! Next week is hopefully going to filled with LOTS more body prep. I am feeling good about it.
Beautiful rocker cover now fitted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas706_zpsdd69af66.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas706_zpsdd69af66.jpg.html)
New indicator stalk, now paired with its wiper stalk buddy (Blatant advert in the background!!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas707_zpsba7aed8f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas707_zpsba7aed8f.jpg.html)
Brake pipe made up and fitted to subframe.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas708_zps0bd55fe8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas708_zps0bd55fe8.jpg.html)
First bit of sanding done. It's SO white now!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas709_zpsbc7761f9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas709_zpsbc7761f9.jpg.html)
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What are your plans for the body leading up to painting?
Thom
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It has been a while I've updated this as Mrs Bounce has recently had major surgery, so I have not been out to the garage much. She's now on the mend and I have turned my attentions to paint. Having looked into various options, I was left with these 3:
1. Give it to someone else to spray. I don't have the budget for this at all. A 4-figure sum is not in my plans so that's out.
2. Respray the car myself. My garage is too small, but there's the option of a decent sized gazebo/tent/temporary structure of some sort and my friend has a compressor with spray gear. And here's where it gets awkward. I have never sprayed before, so would need practice and there's no guarantee I would be much good at it. Add to this the problem of the breathing gear needed for 2-pack (and the legislation attached to not being allowed to spray outside) plus cellulose only really being available via the internet and things were starting to look bad for a spray job. There is of course the option of finding larger internal premises to spray in, but I do not know anyone with such a place plus there would be the additional ball-ache of borrowing car & trailer to transport it there and back. Whoop-di-doo.
3. DIY paint job using rollers. I have done a fair bit of research on this, and as my car will not be a trailer queen/concours vehicle, I am happy with just a half decent shine. So I have gone down the Rustoleum route as they have a wide range of colours, and it's easy to apply with no primer once it's been thinned. Flat down with fine wet & dry then re-coat. And Shaun's just bought a polisher. Plus there's the added bonus of it being much cheaper!
There's only a minor bit of prep left to do, I've now got all the paint and equipment, so will let everyone know how it goes.
I'll just leave these two pics here...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas710_zps1656e9da.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas710_zps1656e9da.jpg.html)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas711_zpsc09f6b50.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas711_zpsc09f6b50.jpg.html)
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This is not fair - I've checked this everyday for the last God knows how long and this is all you give me! :grin:
Good luck with the spray!
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Good to hear Mrs "B" is doing well :cool:
Rollers! Aghhhh!
Priming your bodyshell and panels would teach you how to paint, and something as small as a Midas is an ideal way to learn, and also low cost to materials... lots of "Show cars" get painted in lock ups!
Even with the roller route, your prep work will still have to be impeccable to achieve a decent finish... not ideal, but still very doable,
Looking forward to more progress, keep up the good work
Thom
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No two ways about it - the first rolled coat is on! The only difficulty at the time was getting the amount of thinning right. Originally I'd planned to use 10-15%, but about 17.5% turned out to be better. There were a couple of minor runs but these were only right on the edges. These will all be flatted back before the next coat but I will be leaving it for a week to harden. The overall finish at first shows a few of the darker bits through where it's been repaired but these will disappear after the next coat or two. In the meantime I will have to do the bonnet and doors; shouldn't take too long!
First bit done; no going back now!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas712_zps95c176fb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas712_zps95c176fb.jpg.html)
It's ORANGE! Not gonna lose this in a car park...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas713_zps13f72983.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas713_zps13f72983.jpg.html)
Looks good from the back too. Shaun doesn't. He just looks scary...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas714_zpsa6835510.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas714_zpsa6835510.jpg.html)
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This has been a EPIC read. Fantastic work Mr Bounce!
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Epic colour choice dude, love it. :)
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Not too much to report this week other than I have given Zippy his second coat of paint. It was a much easier process second time around as I think I know what I am doing now. I think that this time round I go for two coats before flatting back. I am thinking probably 4-5 coats in total and it should eventually polish up quite nicely.
I also dragged out the bonnet, painted the underside in satin black, then flipped it over to give it a coat of orange once the black was dry. All went swimmingly until I packed up and left everything outside to dry. I shut the garage door straight on to my freshly painted bonnet. How I didn't swear I will never know...
Underside of bonnet now black.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas716_zps4a1599f0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas716_zps4a1599f0.jpg.html)
More orange.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas717_zpsf17d2c85.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas717_zpsf17d2c85.jpg.html)
And yet more orange. Before I hit it with the garage door. Nuts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas718_zps5654953b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas718_zps5654953b.jpg.html)
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I have put the paintwork to one side for a while as it is taking a lot longer to fully dry than first expected. As I am going to be doing at least 2 more coats with an absolute MOUNTAIN of rubbing back, it can wait for a bit for the paint to cure.
So to fill in the time I thought it would be a good time to refresh my carburettor. It's a standard HIF44 from a 1275 Metro, and as the spindle felt in excellent condition, I decided on a service kit rather than the full rebuild kit, saving myself about £30 in the process. The carb itself, although clean on the outside was perhaps a little less than spotless on the inside. So it was time for a run through the parts washer, with special attention from a toothbrush. Much nicer now, and more pleasant to work with. The only thing I will stress is that you should remember to order a couple of butterfly screws as well, as they aren't reusable. I don't much fancy the idea of a piece of one of the old ones being sucked down into my new engine...
Carb apart, bits in need of a clean...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas719_zps16ba576f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas719_zps16ba576f.jpg.html)
And clean again!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas720_zps765d34ff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas720_zps765d34ff.jpg.html)
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Wow an old oil filled jobby iirc
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Is it Carb clean though? Not had too much experience with them outside of quadbikes/mx bikes but even a single grain of grit would make them cough and splutter. Very annoying. :angry:
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Nice to see good progress on this. Well done.
I would reccomend (based on painful experience) pulling a nylon bristle from a fine brush and using that to make sure all the jets are clean.
It took me 3 goes on my old XT600 carbs before I realised two things:
1. My eyesight is no longer capable of verifying that a jet is clean. (I am 52).
2. A parts washer does not get in to a hole smaller than about 2 mm.
3. The main supply of fuel to the engine is the from pilot jet through much of the throttle range. Still 50% at full throttle.
OK - that's 3 things... :rolleyes: But you get my drift. Check the jets rigorously before you put the carb back together - or put new ones in. (They aren't that expensive).
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Service kit has a brand new jet with it which comes with all the associated bits. All seals, gaskets & O rings have been replaced. And my set of nylon brushes have been put to good use too! :cool:
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Nice to see you are ahead of me on that. Hopefully it will start on the button.
Actually, does it have a start button like the first Minis did?
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I will be making a dashboard from scratch (hopefully based on the MGF item I have in the garage) and yes, I WILL be adding a start button :cool:
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Whilst waiting for some butterfly screws before I can finish off the carb, I thought I might as well start with the dashboard. It has been my intention originally to make my own dash using the MGF dashboard I got free as a base. However, I have come across a number of problems. 1) It is broken and warped, 2) It needs the ends cutting off as the MGF is about 4inches wider inside, 3) I don't have any bits with it other than vents and 4) after cutting it to the right width it is so far removed from the shape it needs to be that I may as well start with something else. So after attempting to modify it to suit my needs, I consigned it to the dustbin. It just needed too much work.
I knew there was a reason that I had not thrown anyway the original dashboard. That said, it is a horrible thing that took the old 1275GT-style gauges (which I hated) and has a monstrosity of a middle section. However, it fits, and I can always modify it. So that is exactly what I have started to do. I covered some cardboard with tape and used it to cover the current dial and switch holes, before covering and strengthening with a fresh layer of fibreglass. The plan is to completely remake the middle section and to have a blank canvas to do something great with. Watch this space...
I need to fill this hole...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas721_zps49523d77.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas721_zps49523d77.jpg.html)
...but not with what this once was.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas722_zps7e3a925e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas722_zps7e3a925e.jpg.html)
So it's time to dig out the original (and horrible) dash cover.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas723_zps4180a965.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas723_zps4180a965.jpg.html)
In the process of adding tape-covered card which will peel off once fibreglass is dry.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas724_zpsfcfb881a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas724_zpsfcfb881a.jpg.html)
First layer of fibreglass on. More modification will follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas725_zps2ec01958.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas725_zps2ec01958.jpg.html)
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I have done a little more work on the dashboard; the plan is to use the five 2" gauges in the pod from the XJ6, along with a digital speedo (the centre speedo I have does not fit!) and a 2" rev counter. I am also going back to a standard Mini heater (it fits nicely and there isn't space behind the Midas dash for all the ventwork, pipes and electrics for the gauges) so will doubtless be rebuilding that as well. There was still the monstrosity of a bulge on the front of the dash. This was removed using a saw attachment for a Stanley knife (brilliant bit of kit!) and finished off with the Dremel. I have partially covered this with fresh fibreglass (I used tape-covered card/wood to stop sagging) but I am only halfway through that part with no fibreglass left...
I am, however, a very happy boy. I had a big parcel turn up at Mum & Dad's the other night, which happened to contain my refurbished gearbox from Guessworks. Having spent a few minutes admiring it the lounge, I was encouraged by Mrs Bounce to actually go and fit it. So after fishing out the gasket set and the new nut & bolt set, on went the gaskets, the half moon seal and the super important 'O' ring - I do actually want some oil pressure when I start the engine! It looks awesome.
Horrible bit cut off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas726_zpsf2b08351.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas726_zpsf2b08351.jpg.html)
New fibreglass where the horrible bit used to be. More will follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas727_zps1c1b6a20.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas727_zps1c1b6a20.jpg.html)
Refurbished Gearbox. 'Tis a thing of beauty. I have now removed it from the lounge.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas728_zps702de783.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas728_zps702de783.jpg.html)
Gaskets on with a smear of Blue Hylomar and half moon seal fitted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas729_zps51f43a67.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas729_zps51f43a67.jpg.html)
No way was I forgetting this little fella!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas730_zps5f0886d9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas730_zps5f0886d9.jpg.html)
Nicely where it should be.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas731_zps9c62ca0b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas731_zps9c62ca0b.jpg.html)
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This is the only thing that brings meaning to my Monday! Great work as always! :afro:
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My pleasure to keep your Mondays great Wherry! :wink:
Right - time to start sorting out the transfer gears & housing. Having had a catastrophic failure of this kind in the past, I wanted to get this right! First to go in was the new idler gear bearing. A few minutes with a a socket and mallet and all was in square. Bounce's top tip is to leave the bearing in the freezer overnight before you fit it - makes life a little easier!
An end float for both the Primary Gear and the idler gear float are recommended at .003" to .006" so some careful measurement was needed. The thrust washer I had was 0.115", and with the first C washer combo I tried gave an end float of 0.18". not ideal, especially as the biggest thrust washer I could get is a 0.124" which would still leave 9 thou, 1 1/2 times the required amount. However, another combo I tried allowed me a 0.012" end float. All I need now ideally is a 0.121" to 0.122" thrust. Amazingly, the idler gear and its shims were absolutely spot on so that's an unexpected bonus.
As I don't have a bigger thrust washer, I turned my attention to my eBay bargain heater. Only cost me a tenner plus postage, but when the box arrived, the front control switch had punched through the side of the box. The seller kindly refunded the postage which made things better and only a small amount of bending put the switch right. The heater body itself was a little scruffy and the pipes were in great nick but it was the matrix I was interested in. Amazingly it seemed fine with only a few marks on it and when I reverse flushed it, the water ran clear after a second, meaning minimal sludge. I have taken the heater body apart anyway to clean it and respray it, and the foam is all shot to hell, so that'll be replaced. I have primed it; just need to get some more paint now.
New bearing in. Easier with a frozen bearing.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas735_zps948d3ab3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas735_zps948d3ab3.jpg.html)
Thrust washer. Not as big as I need it...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas732_zps007a3eb6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas732_zps007a3eb6.jpg.html)
...because this gap is too big for now.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas733_zps65a3ff06.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas733_zps65a3ff06.jpg.html)
Quick calculation. Using the cupboard door is useful when you've run out of paper...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas734_zps11057eb7.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas734_zps11057eb7.jpg.html)
Heater looks ok - especially as it was only a tenner.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas736_zpse5d9d52b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas736_zpse5d9d52b.jpg.html)
Side panels already sanded down and in primer.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas737_zps7938e37e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas737_zps7938e37e.jpg.html)
Matrix will go again. Happy with that.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas738_zpse00c9cc6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas738_zpse00c9cc6.jpg.html)
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There are numerous ups and downs of having a project car, and I have experienced both ends of the spectrum over this weekend. Let's start with the rubbish. At some point in the 80s Austin Rover thought it'd be a very good idea to slightly change the design of their A+ drop gears. They did it JUST enough to make sure that the two different types didn't mesh together properly. Off I went to see Ted at the East Anglian Mini Centre who kindly swapped the primary gear type I had for the one that fitted my idler gear. He even thanked me for cleaning the other one for him. Cheeky bar steward! Once back home I was able to reset my primary gear end float using the new (and expensive) thrust washer I had to buy. Luckily there was only one thou' difference between the two primary gears so I was able to get 0.004" end float - perfectly within the 0.003-0.006" recommended tolerance. Next on went the flywheel housing, so I taped up the primary gear, fitted the clutch oil seal and gently lowered it onto the engine, having chucked on a gasket with some Hylomar. A little persuasion with the rubber mallet and all was happily bolted up.
Next was the clutch and flywheel. I first of all made sure the engine was at TDC. Then the backplate, clutch plate and flywheel went on, followed by the stepped washer. I locked up the flywheel using an old engine bearing (works a treat) and torqued it up. Then had to take it all off again because I noticed that I hadn't put the split pin in the bottom of the housing. I shouted rude words loudly. A lot. After take 2, I was able to put the clutch pressure plate on having made sure all was lined up, then finished it off with the clutch "wok" and the breather.
There's still some minor stuff to do, but I am extremely happy to say that I have just built my first engine. And I feel AMAZING!!
Expensive thrust washer. Worth it in the long run.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas739_zps52c5c53f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas739_zps52c5c53f.jpg.html)
That's better than 12 thou!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas740_zps19836d71.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas740_zps19836d71.jpg.html)
All taped up
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas741_zpsb44a343e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas741_zpsb44a343e.jpg.html)
Housing on and clutch oil seal fitted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas742_zps5484e418.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas742_zps5484e418.jpg.html)
Flywheel on, just before taking it off again - split pin was missing!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas743_zps6c33f825.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas743_zps6c33f825.jpg.html)
Clutch all fitted and ready to go.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas744_zps335c640e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas744_zps335c640e.jpg.html)
I built this. An enormous sense of achievement. I feel proud of myself!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas745_zpse937fff7.jpg)[/URL (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas745_zpse937fff7.jpg.html)
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Any reason you set the engine to TDC before fitting the clutch flywheel? I used to just throw them in any old way on my minis.
I've also done the same with the split pin, although when I noticed the engine was in the car. Doh!
As always a cracking read chap. :)
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Thanks Nick - glad people do take an interest in my work!! :nerd:
I set it to TDC so there's no danger of the C washer falling off and jamming; I have read that when this happens it can be a nightmare to get the flywheel off. Angle grinders can be required... :shocked:
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Thanks Nick - glad people do take an interest in my work!! :nerd:
I set it to TDC so there's no danger of the C washer falling off and jamming; I have read that when this happens it can be a nightmare to get the flywheel off. Angle grinders can be required... :shocked:
I've read about this too and fortunately never experienced it. Did need a huge puller to get it off tho.
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The engine & gearbox combo are now off the stand as I was a little concerned that the bolts being used were under far more strain than they were designed for. Andy came over one evening and I built a little trolley for the engine, then we lifted it down. The alternator mounting bolts had indeed bent - I reckon they would've broken after a while. Note to self: when building a trolley, make sure that the castors you use can take the weight. The trolley now consists of wood, 3 wheels and some broken plastic...
I have practically finished off the heater; Having repainted the casing I have applied new foam to the matrix and the control flap then screwed it all back together. I still need to sort the switch panel but I can't make up my mind whether to re-use the original marking or get my own? I will have a think.
There are still some small bits needing work on the engine; a new oil pressure relief valve & spring went in with a new copper washer, and I have since turned my attention to the oil filter housing and pipe. Of course these were for want of a better phrase "bloody filthy" so I spent about half an hour giving them a good going over in the parts washer. Once dry, they've been primed then given a coat of silver to match the rest of the engine. I have also added the temperature sender to the head and have found the alternator bracket which I have also prepped for paint.
New foam and matrix going in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas746_zps34d31816.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas746_zps34d31816.jpg.html)
Almost done. Needs a wipe down and switch panel sorting.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas747_zps50dd6331.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas747_zps50dd6331.jpg.html)
New oil pressure relief valve & spring in, along with new copper washer. Must touch up that bit I missed!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas748_zps8fddb7cf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas748_zps8fddb7cf.jpg.html)
Engine on trolley. Currently has 3 wheels and a stump. Oops...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas749_zpsa8dd7526.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas749_zpsa8dd7526.jpg.html)
Oil filter housing and pipe primed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas750_zpsfd6f63af.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas750_zpsfd6f63af.jpg.html)
...and painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas751_zpsbafee6ac.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas751_zpsbafee6ac.jpg.html)
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Nice progress again mate.
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I aim to please Nick! :grin:
Just a short update as I haven't done a huge amount these past few days. I have finished off the oil filter housing and pipe and fitted them and also dug out the alternator bracket. I cleaned this (and man was it filthy!) as it had been sitting in a plastic box with a few other old oily bits, then primed and sprayed and bolted it to the block with some new bolts. I also fished out the distributor drive and gave that a good soaking and brushing in the parts washer. Suitably cleaned, it was popped into the block using the tried and tested method of the 5/16" bolt. It's in exactly the right position which apparently means my engine is timed correctly, something I was worried about! The distributor clamp has also been sprayed so this'll be added (along with the distributor itself) once it's dry.
New filter housing & bracket on the engine. Does this count as "bling?"
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas753_zps42796eba.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas753_zps42796eba.jpg.html)
Distributor drive. In the right position. Am feeling suitably smug!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas752_zpsf06dbe27.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas752_zpsf06dbe27.jpg.html)
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Everything on the project has ground to a halt until I can sort this out. I have a problem with the backplate/flywheel/clutch arrangement. All has gone on beautifully but when the engine is turned I get a "clunk" about 90 degrees round. It doesn't happen when the flywheel setup is not there (no engine/gearbox issues thankfully) but it's driving me crazy trying to sort it.
Here's a YouTube link to give you an idea of what it sounds like: https://www.youtube.com/watch?v=6a3yzkgb-Ic
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Can you figure out roughly which reagion the clunk is coming from?
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Well, I have found the cause of the clunk and the reasons behind it. The bearing on the nose of the first motion shaft did not mesh properly with the race in the clutch housing. As a result, when the housing was on, the bearing was put under unnecessary strain and parts of it have broken up. Old race + new bearing = unhappy marriage. My fault entirely. A new bearing has been ordered - now I will need to get my hands on a heavy duty blowtorch, a puller and a pair of circlip pliers. All things I don't have to hand.
As a result, I have mostly been preventing myself from burning the garage down this week...
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It's been a while since I went into the Manroom to do anything as I figured the best thing to do was to walk away until I felt like not smashing the place up. I now have my mojo back so it's time to get back in there!
Armed with circlip pliers, a big blowtorch and a new bearing amongst other things, I tentatively opened the door. I'd already managed to remove the clip from the housing, so using an educational video from Guessworks, I heated the housing with the blowtorch for ten minutes then picked it up and smacked it down on a flat piece of wood. It worked first time. Mojo definitely returning. I followed this up with removing the circlip on the bearing and pulling it off the first motion shaft. It was pretty obvious what had happened. The rear of the bearing had broken up and the bits I had found when I'd taken the engine apart were from there. I'll replace the bearing and race next time but I want to clean everything properly first. I have also started work on spreader plates for the mounts for the rear of the front subframe.
Bearing race out - so chuffed that this worked first time!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas755_zps728f3d7b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas755_zps728f3d7b.jpg.html)
Damaged bearing almost off...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas756_zps3dce9a9a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas756_zps3dce9a9a.jpg.html)
...and showing the full extent of the damage. So glad I didn't try to start this engine!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas757_zps00c301f9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas757_zps00c301f9.jpg.html)
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I had an unexpected couple of hours off today, so jumped at the chance to get into the garage and finish off the engine (again). I had already drifted in the new bearing race into the clutch housing, so that left the new bearing on the first motion gear. This went on with a little gentle persuasion and a new circlip. Having given everything a good clean, I added a new clutch oil seal and once again wrapped up the primary gear. The housing was a bit tight on the dowels so I gave it a little adjustment courtesy of a file, then slid it on with no problem. Then it was simply a matter of once again chucking on the backplate, clutch, flywheel and pressure plate, finishing off with the wok. I have given the engine a good turn and it doesn't clonk anymore. Good!
I also managed to find time to knock up a couple of spreader plates for the front subframe rear mounts - these will need to be tidied up but I can do that on Tink's bench grinder later this week. I'll then give them a coat of paint.
My final job was disassembling the brake master cylinder prior to using a rebuild kit. After cutting through the roll pin with the Dremel I noticed that the reservoir was damaged - it looks like the pin was once pushed into the side of the reservoir. Gotta love eBay... Thanks to a wonderful Mini Forum member, a replacement is on its way. Thanks Phil!
New bearing fitted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas758_zpsa58afb1e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas758_zpsa58afb1e.jpg.html)
Clutch housing on after a short battle.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas759_zps58be7aa9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas759_zps58be7aa9.jpg.html)
Clutch, flywheel & pressure plate back on.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas760_zpsdf740a22.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas760_zpsdf740a22.jpg.html)
Wok tidies everything up nicely.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas761_zpsb748c2d2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas761_zpsb748c2d2.jpg.html)
The engine in all its glory. Again...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas762_zpsa1e3cda2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas762_zpsa1e3cda2.jpg.html)
Spreader plates cut and drilled, awaiting tidying before paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas763_zps29da90f4.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas763_zps29da90f4.jpg.html)
Master cylinder partially dismantled...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas764_zps034214ca.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas764_zps034214ca.jpg.html)
...currently on hold because of a damaged reservoir. Whoop whoop.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas765_zps7d7fa8fd.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas765_zps7d7fa8fd.jpg.html)
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Had some more time so went into the Manroom to get started on the brake master cylinder. I wasn't overly optimistic having seen the state of it underneath the rubber boot. There was a bit of surface rust and the piston didn't seem to move much, but the circlip came out easily enough. The piston however, needed more persuasion. A few energetic taps on a plank of wood saw it finally on the move. Given the horrible black brake fluid that came out, I think it had been sat for a hell of a long time, not just the few months that it was in my garage.
That said, the state of the bore was absolutely fine - I couldn't see any scoring or rust. Have bunged up all the holes using a combination of old brake pipes and grommets, I gave the main body of the cylinder a really good clean with the wire brush, the primed and painted it in satin black. I will reassemble next time.
Hmmm. This doesn't look too promising...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas766_zpsd1209858.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas766_zpsd1209858.jpg.html)
All apart. There was nasty black brake fluid in there. Yuck.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas767_zpse696e6ab.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas767_zpse696e6ab.jpg.html)
Cleaned up and grommeted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas768_zps64ace6cb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas768_zps64ace6cb.jpg.html)
Satin black. Works nicely.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas769_zps5849950e.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas769_zps5849950e.jpg.html)
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I have had a frustrating day. Not because things have gone wrong particularly; it's just that I have had issues being unable to find stuff I thought I had. I am waiting on some red rubber grease to arrive so I can finish off my master cylinder. That's been put on the back burner. Instead I thought I'd turn my attention to the dashboard area. When I first bought the car I tore out the old dashboard, intent on building something different. I am still doing just that, but I will be using a modified version of the original dash cover (which was a bit awful...). I did however cut out the supports to it so these will need reinstating. The first thing I needed to do was to make up some basic fibreglass panels to then be pieced together. I decided that the easiest way to do the long top dash rail would be to use the metal bar that was once part of the vent system and cover it with tape and card so I could use it as a template. So after several minutes' cutting and taping, I couldn't find any fibreglass or resin. Great.
I then put one of my Christmas prezzies to good use and starting sanding the main dash cover with my new mouse sander. I did this with a view to P40-ing any imperfections afterwards. I want to use as little filler as possible as of course I will be cutting holes in it, and then hopefully using a crackle finish paint. So I spent a while sanding and cleaning it ready for the nest application of P40. Which I also can't find. So I will now have to order both some resin and some P40, which means I will probably find both as soon as they arrive. Whoop whoop.
Taped-up metal bar prior to the applicant of non-existent fibreglass.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas770_zps1dc9dc10.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas770_zps1dc9dc10.jpg.html)
Dash cover before hitting it with the mouse.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas771_zps4c419402.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas771_zps4c419402.jpg.html)
And cleaned, ready for the application of non-existent P40. Nuts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas772_zps67b6109f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas772_zps67b6109f.jpg.html)
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I had a small (and I mean small!) packet in the post containing my 18g pot of red rubber grease (slightly bigger than a £2 coin!!). I had also grabbed a full propane gas cylinder on the way home from work so I could use my heater - it's difficult to work in the garage when you can't feel your hands.
It was time to finish off the master cylinder. I cleaned everything up using brake cleaner then proceeded to remove the old seals and the washer from the secondary piston. The seals were a bit stubborn (probably the originals) but a bit of persuasion with a tiny screwdriver saw them off. The new seals were surprisingly easy to fit; I made sure that they went on the right way up. Then it was back into the main body with the secondary piston - it was pushed up as far as possible and the locking pin was pushed in to stop it falling out again. A pair of new seals went onto the outside where the reservoir mounts with a bit more red grease. The primary piston was even easier. I applied red grease as directed & again pushed it fully home. It was a bit fiddly getting the circlip in but after a couple of quid in the swear box (only kidding - I don't have one - I'd never be able to afford any parts...), in it popped. More red grease and the main seal went on. Finally, I clipped in the reservoir and tapped in the roll pin with a smear of copper slip. Aside from a bit of tidying and new brake pipes to be fitted, it's done. And I am a happy boy - Mojo is back in room!
Secondary (top) piston removed and seals off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas773_zps0c73950a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas773_zps0c73950a.jpg.html)
All the insides done, new main seal on the bottom.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas774_zpsc3810296.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas774_zpsc3810296.jpg.html)
Finished - all it needs are new brake pipes and a car to attach it to...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas775_zps31ca9836.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas775_zps31ca9836.jpg.html)
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I received both my new fibreglass resin and tub of P40 in the post then promptly found my other ones round at Tink's. Still, I would've need more anyway...
I need to modify my top rail template as the dash itself is 6cm wider. Nothing a bit of wood and judicious use of parcel tape couldn't cure. Once cured, the new rail was a bit flimsy so I have added more fibreglass as well as some strips of metal. I will then screw it to the sides before fibreglassing the sides and adding some upright supports. The dashboard was simpler - I just gave it a skim of P40 to deal with all the holes and imperfections. There are always some that I will have missed, but one skim is never enough... More to follow.
Template full of resin & csm.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas776_zps090e93b5.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas776_zps090e93b5.jpg.html)
Beefing it up with more resin, csm & metal.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas777_zpsec9fc7fc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas777_zpsec9fc7fc.jpg.html)
Dash after skim of P40. Smoothness will follow...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas778_zps0ec5d062.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas778_zps0ec5d062.jpg.html)
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It's been an interesting, if somewhat frustrating morning. I finished the top rail cross piece and fitted it, only to discover that a) I couldn't fit the dash over it and b) I didn't really need it anyway... Let me explain:
Having peeled the cross piece off the parcel tape-covered workmate, I drilled a couple of holes and fitted it across the dash. I then had a root around in my bits box and found a couple of brackets from the old MG F dash I was going to use. These fitted perfectly as supports. I drilled out a couple of holes and bolted them to the cross piece and lower dash rail. I then offered up the dash cover and found that it wouldn't fit at all. Both the cross piece and the uprights fouled the now modified dash. Not only that, but where I had filled in the "glovebox" hole and centre section, it now fouled on the lower rail as well. Amazingly I didn't scream or set fire to anything. (Since my bearing issues I seem to be much more relaxed...) I applied some much needed modification to the bottom rail using the Dremel.
Then I grabbed the dash cover and fitted it, using the two screw holes at the bottom on each side. I will need to modify it slightly to add two more mounting points, but because the dash is now so much stiffer after the alterations, there should be no need for additional bracing. The downside is that I also need to construct a dash top to include the screen vents. There was one that came with the car, but in usual 1980s kit car fashion, it doesn't come anywhere near to fitting properly. I think I am going to need to get creative... All suggestions welcomed!
Cross piece fitted fine.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas779_zps23565adc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas779_zps23565adc.jpg.html)
MG F brackets were a perfect fit after redrilling a couple of holes...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas780_zps34ae128d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas780_zps34ae128d.jpg.html)
... but the whole set up was binned as it got in the way. So did this.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas781_zps147b7eff.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas781_zps147b7eff.jpg.html)
Dash now fits. Dash top doesn't. Not even close...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas782_zps29cb8af0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas782_zps29cb8af0.jpg.html)
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I stayed away from the garage for a few days to think about the top rail. Am still thinking... Went I went back in I realised I needed to clear up the workbench (again) as it was such a state. This meant finishing off rebuilding the carb, which I had put to one side when I had my bearing issues. When I took it apart, I had painstakingly taken photos of where the springs were. Since then, we have changed computers and I cannot find where the file is. So after an SOS call to the Mini Forum, a very kind chap provided me with some pics (Thanks Stu!).
As the engine isn't a massive state of tune, I haven't done anything special to the carb other than clean the innards and use a service pack as I did not know its previous life. Given the state of the rest of the engine, I reckon it'd been sat in a box for several years. I have replaced the needle with a BDL item as the engine is a very similar state of tune to the MG Metro - it should be a good starting point. The outside is not particularly shiny - in fact it's a bit grubby & pitted but I don't really mind - the insides are beautiful. This car has been built to use, not show, and spending several hours polishing bits won't make it go any faster - 'tis a functional piece of kit! Now all I need to do is fit it to the manifold and chuck on throttle and choke cables. Success!
Slowly going back together with new BDL needle (Apologies for rubbish photo).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas783_zps587d5454.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas783_zps587d5454.jpg.html)
New throttle disc screws applied and split. I didn't want bits of the old ones going down the inlet...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas784_zps14a4c0fb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas784_zps14a4c0fb.jpg.html)
Carb is finished, if a bit scruffy. Really nice inside though!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas785_zps95a3933b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas785_zps95a3933b.jpg.html)
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Had a pretty busy weekend so haven't had much garage time. I have however managed to grab an hour or so and started on a couple of small jobs. The abutment bracket for the carb (and the spacer) were pretty disgusting having sat in a box with other bits for quite a while. I have given them both a clean up and also a coat of primer. I just had enough to do 2 coats and the primer ran out. Got my money's worth out of that can...
I also had a look at the heater valve that I'd got from Guessworks on eBay (cheers John!). The valve itself works perfectly - it just had a bit of surface rust and fine covering of radiator silt on the inside. I split the two bits and cleaned up the metal using a wire brush. There are a couple of pockmarks from the surface rust so a quick blow-over with some satin black and a smear of grease should keep it in fine order. The valve itself will go in with the nest load of washing up. Plastic parts always seem to respond well to warm soapy water! More soon.
Abutment plate and spacer in primer. Platinum silver coat to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas786_zpsa2b5fba0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas786_zpsa2b5fba0.jpg.html)
Heater valve in its component parts - a bit rusty and dirty.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas787_zps30f299d6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas787_zps30f299d6.jpg.html)
Valve mechanism cleaned up. Platinum silver or satin black? Hmmm...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas788_zpseaf0dc0d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas788_zpseaf0dc0d.jpg.html)
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Back to garage and a few more little jobs done. It doesn't look much but it's the little things take time. The carb is now finished and has been put "together" with the inlet manifold, spacer and abutment plate for safe keeping. I have sprayed the metal part of the heater valve (no pictures yet) and have also primed and sprayed the spreader plates I made for the front subframe rear mounts. I also took the time to paint my front hubs. I had put them to one side ages ago meaning to do it and never got round to it. There was also a balljoint that I wasn't 100% happy with so I re-shimmed it and now feel satisfied. The hubs themselves are not perfect but anything is better than the rusty brown they were!
Last of all I have grabbed the driver's door in order to recondition the window winding mechanism and door locks. I will leave the picture of it to amuse everyone. It's a state, and this is the good one...
Carb is finished all bar cables and gaskets.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas789_zpsf5a476f0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas789_zpsf5a476f0.jpg.html)
Spreader plates primed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas790_zpsa54f637f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas790_zpsa54f637f.jpg.html)
...and painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas792_zps01ddcd27.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas792_zps01ddcd27.jpg.html)
Hubs painted and looking a bit more presentable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas791_zpsca8b3758.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas791_zpsca8b3758.jpg.html)
Driver's door internals. Not looking too good at the moment...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas793_zpsa831f584.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas793_zpsa831f584.jpg.html)
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A quick update as I had an hour or two after work this evening. The driver's door needed to be stripped and the first thing I needed to do was to release the window. I used the tried and trusted method of jamming the glass with a block of wood whilst winding the winder down to take the channel off the glass. Some hope. Seized solid. So out came the WD40 and a small hammer. A few taps with a flat blade screwdriver got it moving and it eventually popped off. I will be removing the frame eventually as I will need to replace the window seals but this may take some time so don't hold your breath!!
I then had to remove the plate which holds all the winding mechanism. This was held in place by about a dozen rivets. A few minutes with a drill and they were all out although they did fight a bit. I unhooked the door release mechanism and then withdrew the plate and the window winding gubbins. Unsurprisingly, the winder mechanism was covered in surface rust (as was the plate). I cleaned up the winder mechanism using the wire brush attachment on the angle grinder, masked off the greasy areas and gave it a coat of primer. I shall make sure it looks a lot better when it goes back in.
I am not sure whether to de-rust the plate or make a new one yet; there's only one section of it which looks horrid. However I don't have much steel and if I can get away without making it all the better. On the other hand, the passenger side plate is virtually see-through in places so I might do this one as practice for the other...
Channel removed. I had to hammer it off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas794_zps1e937125.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas794_zps1e937125.jpg.html)
All rivets drilled out, plate removed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas795_zps12f5f80a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas795_zps12f5f80a.jpg.html)
Winder mechanism cleaned, masked and primed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas796_zpsadd6c0d3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas796_zpsadd6c0d3.jpg.html)
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Today I have mostly been playing with metal plates. First job was to see a) how bad the rust was and b) if it didn't appear to be too bad, I should try to remove it. First job? Out with the angle grinder and wire brush and I cleaned up the plate as best as I could. Although the plate looked quite bad, it appeared that the majority was surface rust. A few minutes' judicious use of the loudest tool I have and most was gone, and seemingly only a couple of minor pinholes had shown themselves. Perhaps I was going to be lucky? The next tool in my box was a chemical-based one - Bilt-Hamber's De-Ox gel. I only have one word for this stuff - astonishing. I brushed it on, left it for half an hour and then used a hand-held wire brush to agitate it all into a horrid brown sludge. This is then wiped off and viola! The rust has disappeared. Sadly it also revealed more pinholes and pockmarks than I could shake a stick at.
I am currently looking into places to get a decent amount of steel for as little money as possible. I guess it's cardboard template time... To calm myself I gave the winder assembly a coating of satin black which made it look all pretty.
Rusty. Here's hoping I can make it look a little more useable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20797_zpslpxbdjd9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20797_zpslpxbdjd9.jpg.html)
Potentially still useable - time for De-ox gel to really make sure!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20798_zpso79huldg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20798_zpso79huldg.jpg.html)
Gel on. It really is amazing stuff.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20799_zpsrjot4s6i.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20799_zpsrjot4s6i.jpg.html)
Most of the rust just wiped off after agitation. Still some left, but it had told me all I needed to know...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20800_zpsufj5krdg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20800_zpsufj5krdg.jpg.html)
...that holes like this are too bad to ignore. It's template time. Pass the new steel...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20801_zpswwvj2ezx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20801_zpswwvj2ezx.jpg.html)
Still, at least the winder mechanism looks good now!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20802_zpsdfevsbjs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20802_zpsdfevsbjs.jpg.html)
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Just a quick update tonight. I've finally got back in there and have finished repairing the door plate. I decided that the easiest thing to do was to cut off the rusty section, create a new one out of sheet steel then attach it. I chose to rivet it as a) it is really easy and b) I wanted to try my new rivet gun. I made up a template out of a Shreddies box, then cut what remaining steel I had to size. Then it was a simple matter of bending it in the right places, clamping it and drilling the holes for the rivets and then using the rivet gun to fuse them together. I then gave it a covering of the nearest rattle can to hand, which was stonechip paint. That should make sure there won't be a repeat of such corrosion.
Cardboard template.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20803_zpsximt979d.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20803_zpsximt979d.jpg.html)
Roughly bent to shape.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20804_zpsxvah08rq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20804_zpsxvah08rq.jpg.html)
Riveted on and stonechipped.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/dfaa33b6-c9d5-481c-9aa4-367b90c95eba_zpshtwcgesp.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/dfaa33b6-c9d5-481c-9aa4-367b90c95eba_zpshtwcgesp.jpg.html)
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The Manroom has been in a bit of a state recently and I have the battle scars to prove it as I've been falling over stuff. I spent the entire morning today tidying it up - I pushed the Midas out on to the driveway so I could have more room to play with and it is now a much happier place to be. So much so that it was time to crack on with the doors. The frames needed to come off as it is the only way to get the glass out short of smashing it. I REALLY need to change the channel rubbers and all the other window seals as they're so rotten - not a problem really, but the state of them is quite comical.
First thing was first was to remove the 7 screws holding the frame to the door. 2 of them go through each frame upright with 3 securing the end piece and 2 through the front edge of the top of the door beneath the quarterlight. These were horrible on the driver's door, and I have ended up bending the frame over these as they simply would not shift. Nothing a bit of hammer work won't cure. The others were all fine, with the exception of the screw through the upright near the rear of the door. I had to use an impact driver on this one in conjunction with some WD40. Didn't take too long though as I like hitting things with a hammer. The frame then came off with no real issues, and this was followed by the lock, latch and handle mechanisms. All easy!
The other side was next up. Firstly I drilled out all the rivets on the winder plates (the main one looked horrible!) and removed all the window winder gubbins and the door pull. I then moved on to the frame. The front screws were a struggle - I resorted to Dremel-ing a slot in them - the heat from this allowed the fibreglass to release its grip enough to let them turn. The back 3 again were no issue but the rearmost upright screw was a proper bar steward. Of course the head was just chewed enough so the impact driver wouldn't work and you could not get the Dremel in there to cut it off. I eventually released it using a very small pair of Molegrips, which took forever because I could only move it about an eighth of a turn at a time. Eventually it gave up and the frame parted company with the door.
I cut the rusty bit off the door plate and once again repeated the process of making a replacement part, riveting it on. I then hung it up and gave it a coat of stonechip. Am feeling good!
Frame finally off driver's door.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20806_zps23cwsa3w.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20806_zps23cwsa3w.jpg.html)
Handle and locking mechanism out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20807_zpshwvcsgus.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20807_zpshwvcsgus.jpg.html)
Frame ready for refurbishing.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20808_zpsozcchmii.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20808_zpsozcchmii.jpg.html)
Passenger door ready to be attacked, including...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20809_zpsrkd5tjyr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20809_zpsrkd5tjyr.jpg.html)
...very ugly looking door plate.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20810_zpsuq5zr8zs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20810_zpsuq5zr8zs.jpg.html)
This screw was a pain. I cannot thank the inventor of Molegrips enough.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20811_zpsnlmeclfs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20811_zpsnlmeclfs.jpg.html)
Frame is finally off this one too!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20812_zpsajapdr7z.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20812_zpsajapdr7z.jpg.html)
Repaired door plate in stonechip.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20813_zpsuoniuznb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20813_zpsuoniuznb.jpg.html)
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This thread needs more orange.
Good progress dude. :)
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Plans are afoot Nick. End of May for more orange... :wink:
Isn't it amazing how one small tiny little thing can make your life a misery? When I was taking the car apart, the screw for the passenger window winder was seized and no amount of impact drivers, Plusgas, grinding or heat would shift it. I drilled the head off it to get the winder handle and then the door card off with a view to drilling it out at a later date. That later date has arrived. 3 broken drill bits later plus a LOT of bad language and still only part of the screw has been drilled out. I at first though I would just replace it with a standard Ford part (Fiesta Mk1 or 2), but of course Midas redesigned it slightly by chopping it about and re-brazing with a piece of triangular steel. So out came the drill again, this time a bigger drill bit, and I drilled out the rivets holding on the winder wheelbox. The "new" Fiesta winder should arrive in the next few days, so I will do the same to that, and rivet the new wheelbox back on.
In the meantime, I gave the winder mechanism a new coat of primer followed by a squirt of satin black. I would have masked the wheelbox anyway so it won't be an issue. I also straightened the driver's door frame where I'd bent it on removal. An easy few taps of a hammer on wood had it back into perfect shape. I also removed the window tack rubbers. You can see from the pictures that it *MIGHT* need replacing...
Wiper wheelbox removed from winder mechanism...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20814_zpsxodnvsmk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20814_zpsxodnvsmk.jpg.html)
Because this little so and so was causing me a lot of grief. I'm gonna throw it in the bin!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20815_zps3cpv0xt1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20815_zps3cpv0xt1.jpg.html)
Primed winder mechanism awaiting paint (Apologies for poor pic)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20816_zpse0ydk1ug.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20816_zpse0ydk1ug.jpg.html)
I'm not sure this will go again...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20817_zps7ea1s8bf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20817_zps7ea1s8bf.jpg.html)
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I now had two doorframes sitting around so I thought I had better do something with them, and that something was sand them ready for paint - they were looking a little tired. They are incredibly light (aluminium I believe) so attacking them with the wire brush on the angle grinder was out of the question. No, instead I went for the mouse - it's an ingenious little sanding device that oscillates rather than spins. A bit of 120 grit and all was nicely keyed for a new coat. I wiped them down with a white-spirit soaked rag then left them to dry, before a final wipe with a tack rag. I then gave one of the frames a coat of primer. I only did one as I hardly have any space!!
First frame sanded and put out of the way so...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20818_zpsjbj8zzoo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20818_zpsjbj8zzoo.jpg.html)
...I could get on with the other one. Mouse on bench is an awesome bit of kit.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20819_zpsb5afaxjv.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20819_zpsb5afaxjv.jpg.html)
First frame primed. It's hung upside down on the bar because that bit goes inside the door so any hanger marks will be out of sight.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20820_zpsz28p01x8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20820_zpsz28p01x8.jpg.html)
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Something has been bothering me about this project for a while and that is the fuel tank. There is a small filter in a van tank near the bottom in the middle which is virtually inaccessible, and when I sealed the tank I also managed to seal this. It is virtually impossible to remove at the best of times, but covered with Frost's finest tank sealant it wasn't going anywhere! I have also noticed that there is a horrible section on the tank floor which has made my mind up for me. This tank will not be used. However, I have stumbled across a bargain. When I was at Brooklands Mini day the other weekend one of the autojumble traders was selling a van tank for the princely sum of £35. Considering what they usually go for I was gobsmacked. The inside looked in really good nick and although it had a dent, there was no way I was going to turn it down so it came home with me.
As with most things Midas-related, it is not a straight swap. You need to lop 2 inches off the top of the filler neck. Having marked it up, I grabbed my trusty hacksaw and set to work. All went without a hitch and some gentle filing made sure there were no sharp bits for my poor dainty fingers. There was a bit of a problem with the tank though and that was the paint. The guy I bought it from had it on a van he'd restored and just swapped it out for a new tank. He'd then given it a coat of "paint". I think it is fact more like tar. I got out the most horrible stuff I could find (Halfords equivalent of Nitromors from about 10 years ago!) and coated the top of the tank with it. I then spent the next hour and a half with a scraper getting very messy indeed. I wiped it all down with white spirit afterwards but it still needs a good going over with the wire brush. And I still have the bottom half to do. Lovely.
In the meantime I found a place to hang the already painted frame, then sprayed the other one with primer. Onwards and upwards!
Sealed filter. It was going nowhere. Tank wasn't "right" either so I will get rid of it...
(http://i511.photobucket.com/albums/s353/MrBounce38/Tank001_zps6856ed56.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Tank001_zps6856ed56.jpg.html)
...and it will be replaced with this.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20821_zpscvwlcexx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20821_zpscvwlcexx.jpg.html)
Marked up, first cut made.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20822_zps2qahwgjr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20822_zps2qahwgjr.jpg.html)
No use for a van anymore!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20823_zpsu0vj59ew.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20823_zpsu0vj59ew.jpg.html)
Half the "tar" removed. More work needed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20824_zps8mc5zkyg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20824_zps8mc5zkyg.jpg.html)
2nd door frame primed. 1st one in the background.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20825_zpsc22np0xj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20825_zpsc22np0xj.jpg.html)
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I have finally finished removing the horrible tar-like paint from the other half of the tank. I think the vendor slapped it on quickly before bring it down to sell as it was still tacky when I bought it. It didn't help that it was very thick in places. I am forever grateful for paint stripper and my trusty scraper. The top I was wearing can probably be turned into rags now though... Once the paint was off I gave the tank a wipe down with white spirit to remove any traces of stripper, then gave it a tickle with the wire brush on the grinder to remove any stubborn bits. Another wipe down was followed by a couple of coats of primer - quite difficult when you can't hang it up...
Finally got the last of the "tar" off. Yummy.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20826_zpsgtk7ta2u.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20826_zpsgtk7ta2u.jpg.html)
Primer on both the top...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20827_zpsliunxjbu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20827_zpsliunxjbu.jpg.html)
...and the bottom. Paint to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20828_zpsxi4ydgdu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20828_zpsxi4ydgdu.jpg.html)
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Not much else to report today other than I have finished painting the tank. I put in a new sender unit and used brand new screws. I might even chuck it on the car just to get it out of the way...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20829_zpsojjp4ep3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20829_zpsojjp4ep3.jpg.html)
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I have finally sorted my window winder issues. Well - almost. As the screw that seized in the old winder seemed to be made of diamond and was thus impossible to remove, I did the honourable thing and bought a Fiesta window winder, drilled out the rivets, removed and then re-riveted the new wheelbox on the Midas mechanism. It works perfectly - the thread for the screw was even clean! However, this was when I discovered that Mk1 & Mk2 Fiesta window winders have slightly different splines. Anyone got a Mk2 window winder going spare??
As I am getting nearer to the stage where I can bolt stuff back on to the car, I realised I really ought to sort out the driveshafts. They'd been sitting on the bench pretty much when I removed them from the car (that was in 2012!!) so I dunked them in the parts washer to remove all the grit and old grease - they've come up rather nicely. There were no obvious marks or wear on the inner pot joints, so these will be regreased and reassembled with new boots. I have new outer CVs to go on the other end of each shaft.
New wheelbox attached. Winder required...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20830_zpsoj58szpj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20830_zpsoj58szpj.jpg.html)
Driveshafts & pot joints in need of a clean.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20831_zpsdkigqtr9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20831_zpsdkigqtr9.jpg.html)
Looking a bit more presentable!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20832_zpsdzxlljij.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20832_zpsdzxlljij.jpg.html)
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Once the pot joints were cleaned up, chucking a couple of new boots on the driveshafts was easy. At least it would have been if one of the cages hadn't been put on the wrong way round. The drivetrain on this car has been a bit weird, what with the broken castellated nut on the front end and the "modified" hub. I guess it was no surprise that the driveshaft was going to be wrong as well. So out came the balls (carefully noted where they came from) and I turned the cage to its correct position, subsequently remembering that "refitting is the reverse of removal". Still, could've done without it... I've put the shafts to one side (again) as I won't be putting the CV joints on until I'm ready to fit the subframe.
I have turned my attention back to the dashboard and have done a lot more sanding. However, rather than crackle finish it, I may instead be using vinyl and a heat gun. It could take forever to get this stuff smooth enough for paint, so I will see what vinyl comes my way. I offered up the multi-gauge binnacle liberated from an XJ6 and also made the first hole for my 52mm rev counter. More to follow!
First pot joint quickly sorted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20833_zpsnjkqumpe.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20833_zpsnjkqumpe.jpg.html)
Second one took longer because I had to put it right...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20834_zpsrilzru5i.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20834_zpsrilzru5i.jpg.html)
5-gauge binnacle offered up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20835_zps2iopltiq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20835_zps2iopltiq.jpg.html)
Rev counter hole sorted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20836_zpsmxcfslcz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20836_zpsmxcfslcz.jpg.html)
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Interesting. I never noted which balls came from where when I stripped down pot joints. How the hell did they get it to work with the cage on backwards? Muppets!
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A short update today. It was time to turn my attention to the rear end of the car. I am in the process of ordering some new rear springs so in theory I should be able to bolt everything together and be able to take the car off its trolley and on to its wheels. So the beam came off the shelf and the brackets came out of one of the boxes. Of course it should have been as easy as just bolting everything together but of course that was some hope. If there's one thing I hate about Mini radius arms it's those rubber seals and big washers on each end. Eventually both arms were sorted, both brackets were bolted on and the whole shebang was back together for the first time since 2012. I have laid the braided brake hoses in place because (of course) I can't find my 3-way brake splitter. It's not where I thought I'd left it, so I am currently annoyed. I do however have the (new) brake pipes ready to bend up. More later.
Beam retrieved from the shelf.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20837_zpstpfgsjie.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20837_zpstpfgsjie.jpg.html)
All bolted together. All I need now is brake pipes, a splitter and new coilovers.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20838_zpsopsaqgnf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20838_zpsopsaqgnf.jpg.html)
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I have been a busy boy again so not much to report. I have been having fun (or not) with brake pipes. I dug the compensator valve out of the brake box and realised it was still a horrid colour, so I wire brushed it and gave it a coat of primer & satin black to match the master cylinder. I then grabbed the beam and hoisted it up onto the bench to start dealing with the brake pipes. When I bought the car there was a kit of brand new (Mini) pipes - all except the front to rear pipe, so making up the new pipes was not an issue.
I found my 3-way splitter and bolted it to the beam, then made up the first (short pipe) to go between the splitter and braided brake hose. All went together easily. I then got the longer pipe for the other side - this needed to be bent about a bit as the Midas has a narrower rear track than a Mini. Again, not too much of an issue. Then I once again delved into the brake pipes box to find only one pipe to go from the braided pipe to the cylinder. Typical! There is also a problem with the front to rear brake hose - the ends are different on the one I need. The one I have does not...
I have put an order in to Mini Spares.
Compensator valve looking more respectable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20839_zpsd7vdl3qn.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20839_zpsd7vdl3qn.jpg.html)
Short brake pipe made up and fitted...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20840_zps6r6filbs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20840_zps6r6filbs.jpg.html)
...and longer one bent about a bit to fit.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20841_zpsol9f1xit.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20841_zpsol9f1xit.jpg.html)
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Have completed a few more little jobs and have also got started on something that's been bugging me. When getting my replacement brake pipes from Mini Spares, I also took the time to top up with half decent replacement bushes for the top and bottom steady bars as well as a further steady which is mounted to the gearbox. The car will now have a total of 4 steadies, all without the need for an "ultimate engine steady" - I'm not keen on these.
I sorted the bushes for the bottom steady bar and bolted it to my improved and far stronger bracket on the front subframe then, using the vice, pushed in the uprated rubber one-piece bushes into the top steady bar. Quite why BMC/BL/Austin Rover etc didn't do this to start with instead of waiting until the 90s I will never know but I guess that's "progress".
The brake pipes were easily fitted - a simple matter of gently bending them to shape and screwing them in. One looks smoother than the other due to one being dead straight from the packet and second one being already bent!
Finally, the spare wheel "hump" used to have a captive nut in it and a "T-bar" assembly which had been cobbled together. The captive nut broke off so I had to cut the original out using a Dremel. As I wanted to try the welder again, I got hold of a nut and long bolt plus a piece of 3mm thick steel. I drilled a hole then welded the nut on properly before giving the whole lot a coat of primer prior to some paint. Once finished, I will construct a new T-bar section and glass the whole lot into place.
Bottom steady bar bushed and fitted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20842_zpswjklqeks.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20842_zpswjklqeks.jpg.html)
Top steady bar with new one-piece uprated bushes.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20843_zpso5uziwsr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20843_zpso5uziwsr.jpg.html)
New brake pipe fitted. This is the tidy one.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20844_zpsrdl7pndl.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20844_zpsrdl7pndl.jpg.html)
And the other side, looking slightly less professional.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20845_zpsugyn5jpt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20845_zpsugyn5jpt.jpg.html)
Original "T-bar" section and dodgy captive nut I had to cut off
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas157.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas157.jpg.html)
New captive nut plate sprayed up in primer.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20846_zpsbvdwmgzz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20846_zpsbvdwmgzz.jpg.html)
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Had a few more minutes in the Manroom so I sorted out missing captive nut on the spare wheel "hump" in the boot. I stuck the steel plate with captive nut on to the hump with epoxy resin, and once that had gone off, I screwed a bolt in covered with tape to stop the threads getting gummed up with resin. I mixed up some fibreglass resin and glassed over it with CSM. I also started to make a new "T-bar" to screw in. I used a bolt roughly the same size as before then cannibalised a top engine steady bar. Unfortunately things went wrong - after a poor attempt to weld it all together, I welded the tip of the welder up and when trying to remove the old tip, it snapped off, leaving the threaded part in the nozzle. Oh joy.
Captive nut plate stuck on with epoxy resin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20847_zpslj994lcl.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20847_zpslj994lcl.jpg.html)
Glassed over.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20848_zpsj3u6pkz1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20848_zpsj3u6pkz1.jpg.html)
T-bar midway through construction when the welder broke.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20849_zpsszv6i62y.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20849_zpsszv6i62y.jpg.html)
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I used to eat through those bushes in the upper dog bone. Longest I got a set to last was about 6 months.
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I have had a delivery. I will just leave this picture here...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20850_zpsdpphdneh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20850_zpsdpphdneh.jpg.html)
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You'll love those. I had their dampers on the mini and run their coilovers on the MX5.
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I am SO chuffed with their service Nick. I emailed both Spax and GAZ - GAZ replied and showed real interest whereas Spax's emailed was non-committal and gave an impression of a "couldn't care less" attitude. I rejected Pro-tech as they appeared too expensive.
Instead I had a few emails back and forth with Dave at GAZ discussing spring rates and shock & bush dimensions, then chatted to him over the phone and placed the order. He said it'd be "about 4 weeks" as they would have to be made, then 3 weeks later they turn up. And they were REALLY good value - about £100 less than I had expected. Still need to buy my front shockers, but no prizes for where I'll be getting mine from... :laugh:
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I got the doors down as I needed to a) clean them, b) sand them and c) repair them if there were any cracks. Stupid question, as this Midas appears to have all the cracks in the world. So it was out with the orbital sander and some bits of 150 grit, and each door was cleaned then sanded. I spotted several cracks in each door and, Dremel in hand once more, I set about dealing with them. I ground out each individual crack, then filled them with P40 fibreglass filler. Once dried and sanded down, I gave each bit a skim of body filler.
I wasn't happy with the paintwork on the shell, so I firstly removed the bonnet. Somehow I had missed a shedload of cracks on the very front. My mate the Dremel came out once again and the process was repeated. I then took a long look at the shell out in the daylight. Apart from being filthy, there were parts of the paintwork which could really do with reworking. As a result I have spent a great deal of time today sanding and flatting back so I can start again. I then pressure washed the shell too. I am determined to start putting things back together very soon so will be working hard on this over the next few weeks.
Halfway through sanding door number 1.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20851_zpsme7rhnhj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20851_zpsme7rhnhj.jpg.html)
Were there cracks? Don't be stupid - of course there were...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20852_zpsrygdgyuz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20852_zpsrygdgyuz.jpg.html)
...In fact they were all over the place! I ground them all out.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20853_zpsnyr7pplk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20853_zpsnyr7pplk.jpg.html)
...then I filled them with P40.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20854_zpsqb6cg72i.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20854_zpsqb6cg72i.jpg.html)
How did I miss this load of cracks???
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20855_zpsy8d7fyym.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20855_zpsy8d7fyym.jpg.html)
Skim of filler over the top to finish off.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20857_zpsf5c5su9c.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20857_zpsf5c5su9c.jpg.html)
Shell now not looking quite so "finished"...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20856_zpsrcaingmy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20856_zpsrcaingmy.jpg.html)
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It's been a frustrating couple of weeks, mainly with having very little time to get into the garage. What time I have had has been taken up with sorting stuff that hasn't been car related. Not helpful. When I have managed to get out there, I have mainly been doing filling, sanding and priming - slightly different from just sanding so I do at least feel like I am getting somewhere. The nose is now almost 100% smooth as are the bonnet curves (accidentally "chunked" by my over-enthusiastic use of the orbital sander) and the bulkhead is looking ok too. There are certain bits which will never be great (such as the battery tray) but most of these places will be covered by items such as lights, washer bottles and the battery, so it's not too bad. There are still a couple of places that will need a little more attention, but I am getting there.
Door hinge area on door - now with no cracks!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20858_zpsseyrhioo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20858_zpsseyrhioo.jpg.html)
Bonnet curve mid-sand after filling.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20859_zpslrsp0mqt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20859_zpslrsp0mqt.jpg.html)
Nose area looking a LOT better than before.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20860_zpsy8opdnax.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20860_zpsy8opdnax.jpg.html)
Bulkhead "buttress" - needs a small amount of work on the right hand edge.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20861_zpsmw4vgdqh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20861_zpsmw4vgdqh.jpg.html)
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Had an hour or so tonight so popped back in to do a few more bits. I bought an oil cooler so spent a bit of time cleaning that, then finished off the spare wheel "hump". I hadn't managed to completely cover the plate with the captive nut so out came the fibreglass resin and I cut up some matting to fit. It's now much tidier. Talking of tidying, I also mixed up some filler to use in the small areas where not all was flat. More to follow.
Spare wheel hump now finished. Fibreglass is drying. Paint yet to be applied.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20862_zpsyvfhni2w.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20862_zpsyvfhni2w.jpg.html)
Small smear of filler on the front wing to cover a small indentation.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20863_zps4akmdqsi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20863_zps4akmdqsi.jpg.html)
And likewise on the buttress area.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20864_zpsdzl09avu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20864_zpsdzl09avu.jpg.html)
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It's been a little while since I updated so what have I been up to? Well it's been lots of incredibly dull filling, sanding and priming. In fact it's been so depressingly dull I have taken no photos at all as it's just repeating the same thing on different parts of the car. The garage was also an absolute tip, so I have had a big tidy up.
I came across the bumpers in the tidy up, and I remembered that I wanted to change the way they mounted to the body. When I first bought the car, the bumpers were full of expanding foam and rotten wood. They were also fixed to the car using wood screws. This simply would not do, so I thought about different ways to mount the bumpers in a more stealthy and more secure way. As I had removed all the foam and old wood, the bumpers are now much lighter and of course hollow. My solution is quite simple: make a u-shaped bracket at each mounting point out of sheet steel, weld a captive nut on the inside, fibreglass the u-bracket to the inside of the bumper, then drill a hole in the bodywork to bolt the bumper on from inside the engine bay/boot.
So it was out with the old CAD (cardboard-aided design) - I mocked up the brackets then re-made them in steel. I then drilled holes for the bolts and was getting ready to weld them up. Then the welder wouldn't feed the wire through, so I gave up and went inside.
CAD templates made...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20865_zps9iiibwk5.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20865_zps9iiibwk5.jpg.html)
...and replicated in steel.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20866_zpsiygf8neo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20866_zpsiygf8neo.jpg.html)
Holes drilled and nuts ready for welding, once I can get the poxy welder to work...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20867_zpsjnw7dli6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20867_zpsjnw7dli6.jpg.html)
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Have not had a lot of time this week so this is once again a short update. More sanding, more filling and I was able to get the captive nuts on my brackets welded up round at Tink's. I gave them a coat of paint and have started to make the brackets for the rear. I have made sure that the new brackets will not coincide where the old rusty wood screws once were. More soon.
Brackets looking all shiny and nice.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20868_zpssgjuoejf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20868_zpssgjuoejf.jpg.html)
Cunning use of Sharpie pen to show where to site the brackets at the rear.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20869_zpssmgy3oxi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20869_zpssmgy3oxi.jpg.html)
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More bracket work has been going on. Andy mended my welder so I made more card templates then used the majority of the steel I had left to make up the brackets for the rear bumper. I drilled them and welded on some nuts before spraying them up - the first one looked a little bit splattery but I soon sorted that out. Whilst these were drying I mixed some epoxy resin and stuck in the brackets for the front bumper. I shall fibreglass over the edges as a "belt and braces" approach. It should be dry tomorrow so I will mix some up in the morning.
Brackets made up (before drilling).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20870_zps9r8z45mu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20870_zps9r8z45mu.jpg.html)
New brackets in primer.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20871_zpsoszzk6cs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20871_zpsoszzk6cs.jpg.html)
Front bumper brackets stuck in with epoxy resin.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20872_zpsfd9li0ab.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20872_zpsfd9li0ab.jpg.html)
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be careful as certain epoxy resins will eat away at cured polyester resins (I assume this is what your parts are made from)
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Cheers Wazzzer - no issues here thankfully :nerd:
Another quick update - I have glassed in the first set of brackets (one side only) which all went ahead with no issues. Would have done more but need more paintbrushes... I also made a captive bolt bracket for the pedal box to replace the really thin and badly-made brazed one which came with the car. More next week!
Brackets fibreglassed in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20873_zpsmckh6rtx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20873_zpsmckh6rtx.jpg.html)
Pedal box captive bolt bracket. Not perfect, but FAR better than what was on there!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20874_zpsejy4bai0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20874_zpsejy4bai0.jpg.html)
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It's been a little while so it's time for a quick update. There has been much prepping which is incredibly dull and boring so it really isn't worth writing about or providing photos. Then Shaun came over, brought a couple of things with him and this happened...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20875_zpsrsiqnvrp.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20875_zpsrsiqnvrp.jpg.html)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20876_zps0gbr6ux1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20876_zps0gbr6ux1.jpg.html)
First 2 coats are on; now time for a flat back before adding more. Starting to look more like a car again...
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Glad to see more orange happening. :)
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I am a VERY frustrated man. Couldn't spray before I went on holiday due to the wet weather. Then after getting another coat done on Thursday, I go away for a couple of days and return to more rain. There will be more updates I promise, but they will be weather permitting. I can't really do anything in between as everything else is behind large amounts of plastic sheeting. There is supposed to be better weather next weekend so watch this space...
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Well, I have given up on the spray job until next spring. My main problem was operator error - I was over-excited and tried to rush it which was a bad plan. I mixed the paint badly (too runny) and got drips & runs everywhere so it'll have to be taken back and done again.
So over the winter I shall put the thing onto its wheels by chucking on the subframe and beam, install brake & fuel lines and start sorting an interior. I'll then spray the body once the weather improves again.
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Well I have spent a ridiculous amount of time rejigging and sorting out my garage as I didn't want to do any work on the car. I spent a lot of time correcting bodges (now where have I heard of that before?) and started by removing my workbench which was an old door nailed to some batons. I have had a lot of fun with hammers, jigsaws and runs to the tip. There was also a "cupboard" in the corner which was constructed of two old doors with some other random wood attached. I am kind of annoyed that I didn't take any pictures of this lot but let's just say I have a much nicer working area and fewer crappy old doors. In addition I had to remove and reposition two sets of shelves as well as sorting out what was on them... Finally I have obtained a new stainless steel workbench which is electrically height-adjustable. It's great and was a real bargain. It's also rather heavy, and I have the bruises to show for it when trying to move too much of it on my own.
So now I have a much nicer working environment, (which I only finished yesterday!) what have I done to the car? Very little in fact. I have however remade the captive bolts for the damper mounts as I wasn't happy with the bolts I'd used before. Two thick-ish bits of steel and some time with the angle grinder, drill and file have them ready for welding and painting. And whilst I was at it, I did the same for the captive bracket for the throttle pedal. I shall get the welding done at Tink's next week as a) his welder is better and b) it's not buried under a load of stuff...
Damper brackets prior to welding
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20877_zpsqdcanvdj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20877_zpsqdcanvdj.jpg.html)
And throttle pedal bracket ready to be zipped up too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20878_zpsapkhveba.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20878_zpsapkhveba.jpg.html)
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Well I have not been able to do any welding on my brackets due to illness round at Tink's, so I took some stuff I'd received through the post into the garage. I have decided to fit an oil cooler to Project Zippy, so I removed the old pipe and did a trial fit of the cooler pipes and the cooler itself. I can't really sort out where it's going to go until the engine's in the car, but it was nice to bolt something new on again! I'd managed to get some orange overspray on the distributor clamp so I rubbed that down and gave another coat of silver, finishing the paint in the process.
I have got a new speedo too. I have always been a fan of the 70s Triumph Smiths instruments, and a 120mph Spitfire item (I think) was a bargain at a fiver. I also got the necessary worm and pinion to (hopefully) make it read correctly. They were of course a bit dirty, so out came the parts washer. A quick dunk and brush with the toothbrush and they were looking much better. I will give them a further clean before fitting anyway, but my excuse is that it was late in the evening when I cleaned them!!
Cooler pipes on
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20879_zpsocievzvf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20879_zpsocievzvf.jpg.html)
Cooler on too
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20880_zps1ojsnpns.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20880_zps1ojsnpns.jpg.html)
Newly-sprayed distributor clamp
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20881_zpsafkokmqi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20881_zpsafkokmqi.jpg.html)
Triumph speedo
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/5d2ce814-90fe-4571-96c2-97099f8a875b_zpsajl1wjqz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/5d2ce814-90fe-4571-96c2-97099f8a875b_zpsajl1wjqz.jpg.html)
Filthy - they aren't going in my gearbox like this!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/e0d34600-960f-482a-96f3-3d00c5b39c5b_zpscpt1rjdt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/e0d34600-960f-482a-96f3-3d00c5b39c5b_zpscpt1rjdt.jpg.html)
Much better! They'll still get another clean though.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/6c5bd2b4-dafd-48aa-9696-2a6c1e9af25b_zpsvg6avcbe.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/6c5bd2b4-dafd-48aa-9696-2a6c1e9af25b_zpsvg6avcbe.jpg.html)
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Glad to see more progress on this. :)
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It's been a very poor couple weeks garage-wise as I have done next to nothing on the project. However, I will regale you all with a health & safety related story.
I was never very happy with the captive bolts I'd made up for the shock mounts (which fit inside the bulkhead) as the bolts were too long, and similarly the throttle pedal bracket as my welding was atrocious. I remade the brackets from some thick steel I had lying around then popped to Tink's one evening to borrow his welder - this is a far better piece of equipment than I have. So I popped the brackets in the vice and zipped them up nicely. It was only after I'd finished that I noticed a strange glow from the side of the workbench. Yup, we had a fire. I maintain that this was down to Tink's garage being a tip - it was an old Mr Kipling packet that was burning!! So we both sprang into action and cleared the burning stuff out of the way and away from the garage, stamping it out and leaving it in the rain on the driveway. However, as we were doing this, Tink put his hand on the vice to steady himself - straight on to the newly welded bracket. Ow. His wife told him off for not wearing welding gauntlets. I had borrowed his...
I am due back round there this week - hopefully all will now be forgiven. Let's be careful and not set fire to our friends' garages.
Newly welded brackets. Paint to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20885_zpse9xbtrip.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20885_zpse9xbtrip.jpg.html)
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After a bit of a hiatus, I can safely say it's nice to be back in the Manroom! It was time to finish off the captive bolt brackets I'd made for the shock and pedal box mounts so I primed them before giving them a coat of satin black. To be fair I could've painted them any colour as they'll be inside the bulkhead or hidden behind the subframe but black was what I had to hand.
Next up was sorting out the speedo gearing as my plans had changed since I had the gearbox refurbished by Guessworks. Using his excellent speedo drive calculator http://www.guess-works.com/Tech/ratio.htm I worked out I needed a worm/pinion ratio of 5/17 as opposed to the 7/18 that was in there. Having already acquired the bits I needed it was time to remove, replace and refit. I checked my gasket box and made sure that I had the appropriate replacements, then whipped the speedo drive endplate off. Off came the cover and the part that the cable attaches to. A bit of gentle persuasion had the old worm and pinion out and on the bench. I gave the (already cleaned) replacements a blast of carb cleaner, then after drying I gave them a smear of engine oil. Then it really was a matter of "refitting is the reverse of removal" with the exception of replacing the gaskets.
Captive bolt brackets in primer
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/c022a7cd-ff15-4782-8075-c484e8bd5507_zpszdnmm3pj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/c022a7cd-ff15-4782-8075-c484e8bd5507_zpszdnmm3pj.jpg.html)
Speedo drive endplate off and on the bench
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20887_zps687nnooi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20887_zps687nnooi.jpg.html)
These needed to come out!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20888_zpsq8pyp8uw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20888_zpsq8pyp8uw.jpg.html)
I don't need these ones anymore...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20889_zpsgjxaaz0u.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20889_zpsgjxaaz0u.jpg.html)
New ones installed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20890_zpscrqqcbus.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20890_zpscrqqcbus.jpg.html)
...And all back together as if nothing happened.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20891_zpsh49daomf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20891_zpsh49daomf.jpg.html)
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This thread is awesome. The amount of detail that goes in to a proper restoration is an eye opener for me. I know I would never have the patience to overcome the setbacks and spend the time on all the little bits and pieces that need doing to make it all work properly.
What you will end up with though is something better than the original would have been and probably one of the most satisfying drives you have had.
Keep up the good work. :smiley:.
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This thread is awesome. The amount of detail that goes in to a proper restoration is an eye opener for me. I know I would never have the patience to overcome the setbacks and spend the time on all the little bits and pieces that need doing to make it all work properly.
What you will end up with though is something better than the original would have been and probably one of the most satisfying drives you have had.
Keep up the good work. :smiley:.
Thanks Bandit! I have never set myself a time limit so have no pressure to finish in for a certain event. There have been a number of times where I have come close to setting the garage on fire as I've been so annoyed, but it is starting to come together a bit easier now, and comments such as yours make it all worthwhile. I hope I can continue to amuse, inform and entertain with future updates :cool:
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The Midas now has something bolted back on to it!! However, it has not been without its complications and there's not an awful lot to show for it. Let me explain.
On a Mini, bolting on the front dampers is nice and easy because all you need to do is to pop 4 bolts into the captive nuts on the inner wings. The Midas has 4 bolts to attach nuts to, 2 of which are captive and INSIDE the front crossmember. The top 2 are just chucking a couple of bolts through the bodywork; however the bottom 2 are somewhat different. I have made 2 plates with 2 bolts in (one for each side) as an improvement to Midas' original design which was simply a "D" shapped washer welded onto a bolt to stop it turning. Getting them in is - how's the most polite way of saying this? - a ******* challenge. The only way is to insert it through the hole for the big tower bolt for the front subframe, and it takes a lot of patience and contortion. Forget about putting in/removing split pins from the master cylinders - THIS is the most difficult job on a Midas. I have only managed to get one in so far as it took me close to 2 hours to get it in. I'd love to know how they did it in the factory if they'd already built the body...
Anyway, the passenger side shock mount is on. I am expecting the driver's side to be equally troublesome. Watch this space.
Well - it's done. And I still have one more to do. Whoop-di-doo.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20892_zpseonaiw0o.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20892_zpseonaiw0o.jpg.html)
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Although I have not spent much time in the garage recently for a myriad of reasons, I have struggled for a good 3 hours to get the second captive bolts into the driver's side crossmember without success. I think it's because the plate is just that little bit too wide that's causing the problem, so I am going to trim it down on my friend's grinding wheel and then have a another go. If that doesn't work I may have to resort to more brutal measures i.e. cutting the crossmember open under the dashboard, popping the captive plate in and than glassing it up again.
In the meantime, what else to do? I really didn't fancy spending much time in the garage, so I decided to clean up the expansion tank. This was filthy dirty and had obviously come from a car which had little or no care taken of its cooling system. The inside was covered in a nasty rusty residue and it really needed a clean up. The question was - how? It wasn't exactly an easy thing to get a brush into as it's a weird shape. Once I'd bunged up the pipes, I made a solution of hot water and caustic soda, and left it bubbling away for half an hour, giving it regular agitation. This had no effect whatsoever. So I had a chat to the knowledgeable chaps on the Mini Forum and the best solution was bleach, rice and agitation (I could also have used water & coarse sand, but as I had none to hand, the rice/bleach seemed the easiest option). The rice acts as a a mild abrasive and the bleach does the rest. Many thanks Nick, Kev & Ian for your advice.
Much pouring, shaking, tutting and tired arms later, there was a significant improvement. I then rinsed everything carefully then gave the tank a good clean on the outside using hot soapy water. It's not perfect as there's still a few really stubborn dirty bits inside the tank, but if half an hour with various chemicals won't shift them then not much else will! As I don't have a dishwasher, I might casually pop it into one of my friends' next time they're filling it...
Before, with ugly rusty residue and dirty exterior.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20893_zpswefyoqvz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20893_zpswefyoqvz.jpg.html)
After, looking much more serviceable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20894_zpsfyyfngcc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20894_zpsfyyfngcc.jpg.html)
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Well it's been a while... I have had no motivation to get into the Manroom so I just haven't been in there - for about 5 weeks! So, having had a clean up, I looked at a few of the little jobs that I can be getting on with whilst waiting for the weather to warm up enough for me to spray the car again.
I had a look at a couple of interior bits that will need work, primarily the rear-view mirror & sun visors. The mirror itself is ok, but the light's internals are rusted and useless and the lens has had its retaining clips damaged. My first thought was to build something up where the original light was, but I thought that I would also look at replacing the whole unit. I discovered that these came from a Fiat 126. As there's not too many of these left around today (the engines are popular with the Classic Fiat 500 brigade), I thought it'd be unlikely that I would find anything. Yet good ol' eBay came up trumps. It was slightly more than I wanted to pay, but hey, the chances of me finding another cheaper would be nigh on impossible. Just waiting on delivery now.
The sun visors were also in a sorry state, having been damp in the past, as well as being subjected to some orange overspray (Oops, my bad). My first thought was to replace using some from the same seller I got the mirror from, but his ones looked much the same condition as mine. As I like a challenge, I think I'll have a go at remaking/rebuilding them. At least I know they should be relatively simple...
I had a stroke of luck when helping my friend Tink clear out his garage. He'd been storing a few Mini bits for a friend and there was a sump guard there. My driveway has a few bumps on it, so I asked how much he wanted for it. The text reply was that he couldn't sell it too me - he could give it to me instead, on the condition that I bought cakes in for Tink's garage nights. Guess I'm going to be getting fatter.
Finally, I have pulled out the gear selector as it will need to be extended. Originally my Midas had a remote gearbox and a Cooper S engine, and thus did not have the original extended factory rod change unit. My plan is to cut the steady rod at the lever end and the selector rod nearer the gearbox end so once extended they do not clash. I have cut some 1/2" ID steel tube to a 4 3/4" length, allowing me to sleeve the rods at 1/2" each end of the tube, giving me the 3 3/4" required. The rods have been marked out - I just need to cut and weld them now.
Rear-view mirror ok, but light and switch is knackered. Replacement unit ordered.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20895_zpsme0lxmvm.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20895_zpsme0lxmvm.jpg.html)
Sunvisors showing the after effects of overspray and damp...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20898_zpsbkyfjbjd.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20898_zpsbkyfjbjd.jpg.html)
... on both sides. Time to get creative!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20897_zpsgcuqwxzq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20897_zpsgcuqwxzq.jpg.html)
Nice sump guard for the price of some cakes. Needs a clean but I love it!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20896_zpszns6fgui.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20896_zpszns6fgui.jpg.html)
Steel tube cut to size before tidying it up (you can still see the blue paint from the hacksaw!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20899_zpsfxinjg3r.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20899_zpsfxinjg3r.jpg.html)
Rods marked ready for cutting, sleeving and welding.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20900_zpsg67wxxji.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20900_zpsg67wxxji.jpg.html)
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Coming along nice. Fair play to keeping at it all this time bud
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Thanks Lemski! :cool:
I have received a few items from my eBay splurge, and among them was a can of chrome spray paint. I have struggled to get a decent shine on the tarnished rear light units, so to aid shine I thought I would use some of this stuff. I spent ages with some sandpaper making sure that all surfaces were suitably keyed on both the rear lights and also the front indicator/sidelight units, then gave them a good coat of the stuff in the garage. Have to say I am quite pleased how well it's turned out. There should be a suitable amount of reflection now.
I have also received a full set of manifold studs, brass nuts and appropriate washers, a pair of half-decent windscreen washers and a pair of gear selector mounting bobbins. The mirror and interior light combo also turned up, but the light lens was broken. To their credit the seller has immediately offered to send a replacement lens free of charge. Top bloke!
Newly "chromed" rear light units. They'll do. :smiley:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20901_zps8i8peet8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20901_zps8i8peet8.jpg.html)
Some of the eBay haul. Replacement mirror/light combo to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20902_zps6wyhjrzw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20902_zps6wyhjrzw.jpg.html)
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During my recent garage clear-up (it still looks like a tip) I noticed something about the subframe which I wasn't happy with. The rubber boots on the knuckle joints were starting to perish. I can't remember where they came from, but they should last longer than a couple of years - and that's being kept inside. As a plus point whilst helping Tink with his clearout, we found Matt's pair of Adjusta-Rides, brand new and still boxed. A (very reasonable) price was arranged and they returned home with me. The adjustable cones on my subframe were generic no-name types and although there's no reason why they won't work just fine, I would be happier with a more well-known brand. I also plan to paint the metal part of the cones, as they are looking tarnished.
So after borrowing Tink's cone compressor, I whipped out the old cones and knuckle joints. Whilst they're off I can also fit the top arm rebound buffers - for some reason I had 3 new ones, but when I fitted the cones, I could only find one of them. So that's been put on the list of "must-dos".
Old cones out...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20903_zpsm4fwlunv.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20903_zpsm4fwlunv.jpg.html)
...because of this...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20906_zpstpnpjted.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20906_zpstpnpjted.jpg.html)
...and these...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20904_zpstdtagdbi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20904_zpstdtagdbi.jpg.html)
...and the need to fit these.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20905_zpsq3c1x39a.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20905_zpsq3c1x39a.jpg.html)
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That boots bad considering its done no miles and just sat there.
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Not much more to report other than I have taken out the bottom arms, end plates and doughnuts and have given them a coat of the same paint as the engine, radius arms and hubs. The top arms were bought painted in a slightly different shade of blue - although I thought it wouldn't bother me, it did start to niggle so as I had everything apart, I may as well give them a fresh coat. I have also fitted the 2 new top arm rebound buffers, but I think they're so boring I didn't bother taking a picture...
Freshly painted doughnuts, top arms and...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20907_zpsguzniq7s.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20907_zpsguzniq7s.jpg.html)
...end plates. Those aren't chips by the way - it's light reflecting!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20908_zpsn3evkbmy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20908_zpsn3evkbmy.jpg.html)
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I have a clean (er) garage. This meant that I could once again drag out the subframe and refit the doughnuts, new Adjusta-Rides (SO much lighter than the copies!) and knuckles and of course the repainted top arms. Out came the cone compressor and after a short while remembering the best way to put everything back together, both sides were back in and tightened up. I even managed to line up the word "Dunlop" so it showed through the front opening of the suspension tower - I'm a bit OCD like that.
I have finally got hold of a new lens cover for my "new" interior mirror/light combo. I was originally going to return it but he found some new lens covers and for my inconvenience sent 2. Ironically I'd bought another mirror in that time, but this had a broken lens too. So I now have 2 complete mirrors. Erm...
Newly painted doughnuts, freshly fitted with...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20909_zpsgq0susyn.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20909_zpsgq0susyn.jpg.html)
...genuine Adjusta-Rides. Lovely.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20910_zps6tehqrkb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20910_zps6tehqrkb.jpg.html)
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Thats cool mate.
How long til hes rolling about again
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Just got to respray the topcoats again then add the fuel & brake lines & put him back on his wheels. Too cold to spray right now... :cool:
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Too cold, was warm here today. Although we woyldnt spray a tractor just yet so I see your point
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It appears I have had a massive upturn in fortune. I have been a bit down and disheartened due to my inability to get the captive bolts for the right front shock mount in place. It's very possibly the most inaccessible place on a Mk1 as the only way to get to it is though the big bolt hole for the subframe on the crossmember. In theory you can cut a hole under the dash and go in through there, but I really didn't want to cut the car about. I went into the garage today with a "Never-say-die" attitude, full of intentions to make the thing fit.
I decided to grind some of the excess metal away on the bolt plate (I thought that it was snagging on the edges), taking all the corners off using the Dremel. It still wouldn't play ball, so I did some more "adjustments". After 2 1/4 hours' of patiently fiddling about in a dark hole, it suddenly slotted into place. I quickly jammed a screwdriver down there to stop the plate moving back, put the shock mount in place and nipped up the nuts. FINALLY I had SUCCESS! And if anyone thinks I'm taking it off, you can forget it!!
There were a couple of other little things I completed today which thankfully didn't need anything like the effort required for the shock mount. I had no holes for the windscreen washers and no windscreen washers themselves. I secured a couple from eBay for buttons and drilled holes for them, having taken careful measurements (the original holes had been filled in as a) I wasn't sure what type I'd be using and b) I don't like the original Mini ones. The final thing I did was to pop the captive bolts in for the throttle pedal. Thankfully I could see what I was doing for this one...
Windscreen washer. These will be taken out before I spray the final coats.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20911_zps9zfhcvkk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20911_zps9zfhcvkk.jpg.html)
Captive nut plate for the throttle pedal now in place. Will be hidden behind subframe tower.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20912_zpsmmtd5flg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20912_zpsmmtd5flg.jpg.html)
You have no idea how happy I am to see those nuts done up... SHOCK MOUNT IS ON!!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20913_zpsrbnx4xwz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20913_zpsrbnx4xwz.jpg.html)
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Back in the Manroom again today and it was time to re-do a job. This is something I hate doing, especially as it was out of my control, but also (kind of) my own doing. When I renewed the rear wheel bearings, I used budget bearings, and when the time came to torque up the hub nut, they hubs locked solid. So I have knocked out the bearings and races to await the new Timken bearings that are on their way. Am not happy. I should have saved for the Timkens in the first place...
I have started to tart a few bits up on the rear hatch, namely the lock surround and hatch handle as well as the roundels that sit on the glass where the gas struts attach. To get the lock and handle off, I first undid the bolt that holds on the lever arm to the lock, then slid out the lock mechanism. Then I undid the 1" nut which holds the lock surround on and took it off. Some wet & dry later, it was ready to be primed. I followed this up with removing the bolts/lugs for the struts from the roundels, and cleaned both the lugs and the roundels. Out came the primer, and once that was dry, I hit it all with some satin black.
Finally, my friend gave me a number plate light he had no use for. This was perfect for the Midas other than it was chrome. So once again it was sanded, primed and given a coat of satin black. I measured carefully and then drilled pilot holes for the screws to hold it in place. I fitted it for posterity - it'll come off when I repaint the car but hey - it looks good!
Rubbish bearings removed. Timkens to follow.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20914_zpsp9le5fex.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20914_zpsp9le5fex.jpg.html)
Large nut holding on hatch handle & lock surround.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20915_zpsup6tttzq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20915_zpsup6tttzq.jpg.html)
Primed surround and handle...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20916_zpspjpvp3t8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20916_zpspjpvp3t8.jpg.html)
...and also a lick of the grey stuff for the roundels.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20918_zps10c6twxa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20918_zps10c6twxa.jpg.html)
A coat of satin black for the hatch handle & lock surround...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20917_zpsmnadd853.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20917_zpsmnadd853.jpg.html)
...and also the roundels and lugs.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20919_zps62aqc1u1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20919_zps62aqc1u1.jpg.html)
And I am super-pleased with the number plate light. Looks great!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20920_zpsa3xaz6st.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20920_zpsa3xaz6st.jpg.html)
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Muchos gracias Gentlemen 8-)
Today has been a long day. I have spent close to 6 hours in the blazing sunshine. However, I wasn't lazing about - I was sorting the shell, doors and bonnet ready for some more paint. Having left the bodywork for 8 months after my painting mishap (LOTS of runs due to making the paint mixture too runny - all operator error!) it was in dire need of sorting out. All the blemishes have been looked at, filled, sanded, cleaned etc. This car will never have a perfect paint job, but then I don't have a few thousand to fling at it so someone else in a bodyshop can charge me £75+ an hour.
I first of all took out as many of the runs as I could find (which took FOREVER!) then filled all the little nicks that had occurred when brushing past it/dropping things onto it/accidentally pushing it into stuff. I then hit the whole thing with 600-grit so it's smooth-ish but the new paint will have a key to adhere to.
Tomorrow I will clear out the garage, put up plastic sheeting, re-mask the car and use Shaun's compressor that I have just borrowed. Watch this space...
Bodyshell after sanding out the runs.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20921_zpswh7zirwc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20921_zpswh7zirwc.jpg.html)
A few minor imperfections in the doors...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20923_zpsi3fonoxk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20923_zpsi3fonoxk.jpg.html)
...and the bonnet.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20922_zpsocmiwls9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20922_zpsocmiwls9.jpg.html)
All sanded and primed ready for more colour.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20924_zpspwrqgvze.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20924_zpspwrqgvze.jpg.html)
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Cant wait to see fresh paint bud. Going gloss finish
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Paint is on hold for now due to the temperature having dropped off again. However whilst round at Tink's, having helped him clear out, modify and generally sort out his garage, we started sorting the gear selectors. For those that don't know, the rods are extended by 3 3/4" due the Midas being longer. I already had the sleeving cut to 4 3/4" in order to put 1/2" of selector rod inside each end.
Out came hacksaw, and the change rod was suitably split. Using carefully placed clamps, we tacked the sleeve to the rod at both ends, before welding it properly. I will attack the welds with the Dremel to smooth them out a bit before some paint. Although I have cut the steady rod, we havent welded it yet due to running out of time. Each welded extension is at opposite ends to avoid the wider rods clashing. More will follow soon. Apologies for the poor photos - I only had my phone!
Selector rod completed. Welds yet to be attacked by the Dremel.
(http://i511.photobucket.com/albums/s353/MrBounce38/20160519_211737_zpseiesbyo0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/20160519_211737_zpseiesbyo0.jpg.html)
Steady rod clamped awaiting attention from Tink's big MIG.
(http://i511.photobucket.com/albums/s353/MrBounce38/20160519_211746-1_zpslahq0dib.jpg) (http://s511.photobucket.com/user/MrBounce38/media/20160519_211746-1_zpslahq0dib.jpg.html)
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I finished off welding the gear selector last Thursday round at Tink's. It was a 5 minute job, just needing to tack it in place then weld all around each end of the extension to the upper steady bar. Just need to tidy it up with the Dremel before giving it a coat of paint.
It was Bank Holiday weekend, and surprisingly, the weather was good. So out came EVERYTHING in the garage and I set to with the staple gun and the large polythene sheets that Shaun had got for me. No more overspray on stuff! Once inside, Zippy was given 5 coats of RAL 2008 bright red orange and although there's a couple of small imperfections, 2 drips (in virtually unseen places) and a couple of bugs, I am pretty please with the outcome. It'll never win a concours or be given good marks by a professional, but hey - it's not a show car - and it's ALL my own work. The bonnet and doors will be done at a later date as I will need to lie them down to do them and there isn't the space - plus it's too cold and a bit damp today. I am, however (much to the relief of Mrs Bounce) VERY happy.
Extended gear selector, just needing a tidy-up before paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20925_zpsj0fqqweo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20925_zpsj0fqqweo.jpg.html)
Zippy appears to have strayed into Dexter's lab...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20926_zpsbqtczpng.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20926_zpsbqtczpng.jpg.html)
SO MUCH ORANGE!!!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20927_zps011jwc3o.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20927_zps011jwc3o.jpg.html)
Looks good from this side too!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20928_zpslnrx6cut.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20928_zpslnrx6cut.jpg.html)
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Looking good and a major step forward. Well done.
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Thats top work buddy. Obvously cant say how good the paint is but on picture its definately good enough for a diy job.
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Thanks to all for your kind words. If I am being honest and my own harshest critic, it's definitely a "10ft paint job" but for a first effort in a single garage. it'll do for me.
Typically, I set aside a really nice day to put what I hoped were the final coats on the bonnet and doors, and after 3 light coats (not enough as some of the primer is still showing through), I ran out of paint... I will get some more and finish them off but it's still frustrating.
So, in an effort to "turn a frown upside down", I decided that it was time to bolt a couple of bits on to the shell. Why? BECAUSE I CAN NOW!! First up was the heat shield for the bulkhead. Given that the one that was on there when I bought the car looked like an old piece of carpet which had been stuck on with silicon sealant, I thought something a little more suitable would be required. After some advice from a Midas forum member (thanks Roy!) I picked up some adhesive heat shielding from Europa Spares and after cutting it to shape, I gently laid it on. I did get one crease in it (which looks far worse in the picture than it actually is) but it won't be seen much and once this stuff is on, it does NOT want to come off...
I followed this up with my captive bolts for the pedal box. I had constructed this from the old cut-down bolts that held it in place originally and a broken disc shroud from the spares box. I hammered it flat, bent it to shape and welded the bolts on before painting it. It slid into place really easily and attaching the pedal box was simplicity itself from then on.
I was on a roll. My next thought turned to the brake master cylinder and the PWDA valve. I popped the master cylinder roughly into place and next up were the brake pipes from the cylinder to the valve. I'd bought these from Mini Spares rather than make my own as they're an odd size, so they came ready bent to shape. I fitted them to the valve first before offering the valve up to the bulkhead. The previous braking set-up was a mixture of single line and utterly knackered so this was all binned and replaced with dual-line. This meant that the PWDA valve needed a home on the bulkhead, and typically this was exactly where the throttle cable used to sit. Modifications are underway to alleviate this issue.
Finally, in went the bracket which the steady bar bolts to. Again this was a simple case of popping a couple of bolts through the bulkhead and connecting them up, albeit with a strangely contorted body upside down in the footwell in brutally hot sunshine. I will bolt some more stuff on soon!
Heat shield on. Ignore the crease - it looks a lot better in the flesh!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20929_zpsehva6oen.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20929_zpsehva6oen.jpg.html)
Captive bolt bracket for pedal box attached. Garage ingenuity made this!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20930_zpszbs7ohvb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20930_zpszbs7ohvb.jpg.html)
Bracket for master cylinders. It's starting to come together...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20931_zpsvtfw4bzf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20931_zpsvtfw4bzf.jpg.html)
Reconditioned "Yellow tag" m/c, PWDA valve, those nice looking pipes from Mini Spares and the steady bar bracket all in place and ready to go.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas20932_zpsnebrobzk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas20932_zpsnebrobzk.jpg.html)
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A couple of weeks ago, I finished off painting the doors and the bonnet. At least I did up to a point. I had got everything out of the garage and popped the bonnet and doors on three separate tables. All went swimmingly, until the last pass of the gun on the bonnet. I hadn't realised that I had not tightened the lid on the gun's container properly, and as I did the last pass with a flourish, 5 paint drips happily landed right in the centre of the bonnet. Oh goody. They say bad things come in threes. They do. I managed to knock one of the doors and chipped the edge. And as I was putting the stuff back in the garage I caught the side of the front wing with a metal box. This made me angry.
As it's always a good plan not to do things when you're angry, I left it a week or two before sanding everything down (AGAIN!) and then giving them a blow over this morning before the rains came down. The bonnet is much better, and the door and the wing will stand up to a 10-foot check. 3 bugs did land on the car though. However, there will be other bug splats in the future so they can stay there until the paint's dried properly!
Painted (hopefully for the last bleeping time!!) and lookin' good!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20933_zpspmbhcy15.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20933_zpspmbhcy15.jpg.html)
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Good progress. What made you go orange? Being a full respray you could have chose any colour.
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Well, it's only 11 ft long and quite low, so dirty white doesn't really stand out. I have always wanted an orange car and there aren't many about. Plus it looks great in orange!
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It does seem to show off the lines of the car in orange over white
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Managed to grab a couple of hours over the last couple of days. I need to get under and do the brake and fuel lines, but this can wait until I have the time to throw everything back out of the garage so I can get the car high up on stands. In the meantime, I painted the extended gear selector rods (mainly to stop them rusting) and then set about de-rusting a few brackets and bits. The door glass holders had a bit of surface rust, as did the gear selector bracket and the engine mount bracket.
I found my pot of Bilt-Hamber De-Ox gel and gave them a good coating having given them a wipe down with white spirit. After half an hour I gave them a good wire-brushing and most of the rust came off as sludge. This stuff is amazing. No pictures of the result as they look much the same, just with not much rust. I will give them a coat of paint in due course. I will also give the gear selector housing a new coat of silver - once I actually get some fresh paint...
Rods won't rust as easily now.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20934_zpspamc8gvh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20934_zpspamc8gvh.jpg.html)
Brackets covered in De-Ox Gel.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20936_zpsegoa69ta.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20936_zpsegoa69ta.jpg.html)
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Just a quick update - have finished off cleaning the brackets I de-rusted and have now given them a fresh coat of Rover Platinum Silver along with the gear selector housing. Looks a lot better than before.
Housing looks a lot more presentable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20937_zpssehnyxl8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20937_zpssehnyxl8.jpg.html)
Brackets are now worthy of going on to freshly painted car.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20938_zps01dfobls.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20938_zps01dfobls.jpg.html)
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Did a few little jobs yesterday, most of which I don't have pics for. I finished off the gear selector and bolted it all together with some fresh grease and it looks rather good.
One of the things I wasn't entirely happy with was the state of the flywheel bolt locktab when I put the engine together (I had made a mental note to change it but didn't get round to it). A new one was found in the darkest recesses of the spares box (I knew I had one somewhere!) and after some grunting and use of the big breaker bar, on it went. Staying with the engine I also chucked in the new set of manifold studs I had and also changed the thermostat housing, removing the sandwich plate that I am reliably informed will not fit under the bonnet without surgery. More soon.
Good looking gear selector housing now bracketed up and finished.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20939_zpsxnnoqubm.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20939_zpsxnnoqubm.jpg.html)
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Another quick update - should be a longer one but my efforts were somewhat thwarted. Let me explain. Before I start doing things like putting on the rear axle and front subframe, I need to sort out the brake and fuel lines. The fuel line itself is fine after a blow through and wipe down as I'd cleaned it a few years, but because I changed from a single to a dual line braking system, the front to rear brake pipe is different. I had bought one for the project many moons ago and it's been hanging on the garage wall for a year or so. Amusingly, it has some orange overspray on it... Of course, the body was sitting on its trolley, something it's been doing for quite a while. Up went the front, followed by the back and the trolley was removed for the first time in years.
My plan with the brake and fuel lines was to re-use the clips which were factory fittings. Unfortunately (and unsurprisingly really) they were utterly crap. You could push the line in and it would hold for a few seconds before pinging out and, in this case, hitting me in the face. I had a few P clips but unfortunately the wrong type of bolts to fit them. I shall get some cap head bolts with a dome as they'll be the least obtrusive option as they will sit on a raised section under the carpet. I managed to get a couple of clips in on the bulkhead and the brake pipe is bent to shape. I just need to replace ALL the clips... More to follow.
Rear brake pipe fitted (but not entirely finished). Sorry about the overspray and amusing spiderweb!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20940_zpserwexebr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20940_zpserwexebr.jpg.html)
It's finally off its trolley!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20941_zpskwucdqki.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20941_zpskwucdqki.jpg.html)
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Well I haven't updated this for a bit because of three factors: 1) Time (I haven't had much); 2) Weddings (we've been invited to SEVEN this year) and 3) Heat. Anything over about 22 degrees and the Manroom turns into an oven. I think I accidentally gave myself heatstroke the other weekend as a result...
Anyway, Mrs Bounce gave up half an hour of her time by wielding a screwdriver, thus allowing me to fix the front to rear brake line with new P clips. The old factory fitted clips really were (for want of a better word) atrocious, so there was no way I was going to re-use them. I still need to do the fuel line, but I am sure I can grab an assistant from somewhere.
This morning I had a couple of hours so I did some little jobs (which of course take a bit of time). I resprayed the areas of the bulkhead which had been affected by overspray, as well as removing the brake valve, master cylinder & bracket as they too had been affected by the dreaded "orange fleck". I masked these and gave them a fresh coat of satin black.Whilst this was drying I popped in the bolts for the top of the front shock mounts. It's a really small job, but something that makes me feel good - another small bit is on the car. Finally I have started work on fabricating a small bracket to allow a more standard looking battery clamp. The previous one was bolted to the bulkhead "buttress" and looked dreadful. More to follow.
Bulkhead looking tidier.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20942_zpsbuvlgsai.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20942_zpsbuvlgsai.jpg.html)
Upper shock mount bolts finally in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20943_zpsyss0pude.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20943_zpsyss0pude.jpg.html)
New cap-head bolts on fuel line side awaiting new P clips underneath.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20944_zpsj8kze1ao.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20944_zpsj8kze1ao.jpg.html)
Not-so-black bits now black again!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20945_zpssyhpgtux.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20945_zpssyhpgtux.jpg.html)
Bracketing under construction.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20946_zpsjhseqt9z.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20946_zpsjhseqt9z.jpg.html)
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Some more progress has been made - there's been a small step back but that's hopefully sorted.
When I chucked the pedalbox in, I of course didn't check where the pedals were sitting. Due to the spring, they were sitting somewhere up near the dash shelf. And because of the design of the bulkhead, I couldn't get them back down without removing them. So I did just that, removing the homemade captive bolt plate, re-positioning the pedals, before holding them in place with something heavy (in this case my bowling ball in its bag - and even that struggled). I nipped up the nuts on the captive bolts and they sit where they should now.
The next issue was the master cylinder bracket. This was the original item on the car, which ran a single-line master cylinder. The main seal is significantly larger on the dual-line master cylinder (9mm difference in diameter!), so it won't fit properly in the bracket. The pedalbox is not an issue because the seal tapers - at least that's what I am hoping... So first thing was to cut a bigger hole in the bracket - no problem I thought - I have hole saws in my set of drills. The only trouble was, this was a cheap set of drill bits (it was a present), and all the hole saw did was make a small mark, get very blunt and cause the wood underneath the bracket to smoke wildly. However, I am nothing if not resourceful. Using the hole saw mark, I cut several slots in the metalwork, bent them out with pliers and then cut them off with the Dremel before giving the whole thing a tickle with the grinder and tidying up with the grinding stone. Granted it's not particularly professional, but now there's lots of clearance and nothing catches. Just needs a coat of paint and all should be fine.
The other day Shaun came over and despite him having a horrible week at work, I put him to work holding the screwdriver whilst I sorted the P clips underneath holding the fuel line. It still needs a couple of more accessible clips in the engine bay doing (and holes drilling for them!) but the awkward bit is done. Whilst I was underneath, I also sorted the remaining heatshield for the exhaust. Again, it's not perfect, but the only person seeing this will hopefully be the MOT tester, and the majority of it will be hidden behind a subframe, a gear selector and an exhaust so I am not too bothered about how it looks - it's for stopping the bulkhead catching fire, not looking good. This of course left me the wonderful task of the steering rack. Anyone who's done one on a Mini will know that they're utter bar stewards when the subframe is on, so I was glad to put it on now, without that large lump of metal being there. It's still awkward when you're doing it on your own, but a carefully placed piece of wood allowed me to pop the U-bolts through (no I didn't forget the little plastic anti-friction strips). I nipped up the bolts to hold it there, although it does need a small amount of adjustment which can wait until next time. Finally, I popped the freshly repainted brake valve back on the bulkhead. This took significantly longer than expected due to the inaccessibility of the nut, but some careful use of a small socket and believe it or not, some cable ties sorted the situation. More soon!
Pedals now where they should be.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20947_zpsersqanrw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20947_zpsersqanrw.jpg.html)
Hole saw a bit rubbish? No problem - use a bit of back-street engineering!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20948_zpshalr76zc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20948_zpshalr76zc.jpg.html)
A tickle with the grinder and it looks acceptable. It won't be seen anyway...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20949_zps5ahgbnaj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20949_zps5ahgbnaj.jpg.html)
Fuel line now held in place - cheers Shaun!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20950_zpsfwyyynav.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20950_zpsfwyyynav.jpg.html)
Heatshield now fitted up to the selector area
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20951_zpsvqrjpb6n.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20951_zpsvqrjpb6n.jpg.html)
Rack now loosely in place.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20952_zps4gcffrh2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20952_zps4gcffrh2.jpg.html)
And brake valve fitted to the bulkhead.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20953_zps8ewy5b3i.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20953_zps8ewy5b3i.jpg.html)
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I don't like Mini braking systems. Mainly because over the years they've been messed about with BL / Austin Rover / whatever they were called that week penny-pinching numptiness. The plan was, as my single-line Cooper S Master Cylinder was kippered, to convert to a dual-line system using a yellow-tag MC and limiter valve on the bulkhead as I also wasn't keen on using the rear valve (VERY rusty). To date I have acquired brand new brake lines all round, an FAM7821 valve (Secondhand) and have rebuilt the s/h yellow tag MC. All new front to rear brake line is fitted. Excellent I thought - I will connect everything up.
Problem 1: The thread to the rear brakes on the valve is knackered. Tightens up so far and then spins on itself. And as it's a blind hole I can't re-cut the thread. New valve then - that's £87 I don't have.
Problem 2: My yellow tag MC and brand new clutch MC do not fit together on the same base plate. There's precious little clearance between them, but add a couple of pipes and they simply don't fit. I am either doing something drastically wrong or fitting a yellow tag is simply out of the question. To put it back to the way it was, a new Cooper S single line MC is £72 I don't have, plus I would need the regulator valve at the back (another £73 - and it's out of stock).
I have closed the garage door and walked away before I pick up something dangerous like a blow torch and some petrol.
This is junk...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20954_zpsth48pdqv.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20954_zpsth48pdqv.jpg.html)
...and these two bar stewards don't fit together.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20955_zpsdxuvmmfy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20955_zpsdxuvmmfy.jpg.html)
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Cant you elongate the mc holes a little to allow you to slightly rotate it and make the clearence?
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Well, it seems that things are looking up again. Thanks everyone for your suggestions and offers of help. It seems that the original "tin can" clutch MCs are the ones to go for, so have a s/hand one coming which will be reconditioned before fitting (trial fitted first of course!).
In the meantime, the brake valve Ian had in his shed (cheers matey!) has been received, and tried out. No issues with the thread on this bad boy - it tightened up a like a dream. However, it did look a bit... how do I best put this... used. So out came my favourite tool - the angle grinder with the wire brush attachment. It made short work of the minor surface rust and odd paint, and I wiped it down before plugging up the holes. I've given it a coat or two of primer before it'll get the satin black tomorrow.
I also finished tidying up the "T-bar" I made to hold in the spare wheel and gave that a coat of primer too. More to follow.
Brake valve looking pretty again.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20956_zps5kt3m2zj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20956_zps5kt3m2zj.jpg.html)
T-bar primed.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20957_zpspgzfevjs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20957_zpspgzfevjs.jpg.html)
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Forums. There's only one thing that I can say about them - they're brilliant places. Not only did I get myself a brake valve from Ian, but a "tin can" clutch master cylinder turned up for sale at a very reasonable price as well. So after a short email conversation involving the wonders of Paypal, I had myself the part that I needed - well, mostly. I knew it would be a used item, so the best thing to do would be a recondition, despite it working well before removal. So I picked up a seal kit (not expensive - about £7) and when the MC arrived, I started on making it more presentable.
It had been on a fuel-injected Mini all its life (one of the later ones) but it was still 17 years old. It was also a little bit in need of a clean. So I removed the circlip, and took all the inner gubbins out before giving it a good dunk in the parts washer, followed by a proper clean up with various brushes and the Dremel. Once properly dry, I gave it a couple of coats of primer, followed by some satin black. I've replaced all the seals - now all that remains is for it to go back together.
Oh, and yes, it fits perfectly!!
As received. 17 years of grime yet to be removed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20958_zpswrx8ljlm.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20958_zpswrx8ljlm.jpg.html)
Much cleaner after a dunk and a brush.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20959_zpse12c6lwe.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20959_zpse12c6lwe.jpg.html)
All the inner workings ready to be replaced
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20961_zpsdudxlttt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20961_zpsdudxlttt.jpg.html)
Primed...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20960_zpstovncsna.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20960_zpstovncsna.jpg.html)
...and painted.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20962_zpsvm3j2n9r.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20962_zpsvm3j2n9r.jpg.html)
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This car is fighting me. A lot. It's almost like it wants to frustrate me at every given point just to irritate me a little more than before. Allow me to write the latest tale of woe.
I finished off the clutch master cylinder by popping in the spring and piston with its new seals and washer and sorted the circlip with a flourish. Everything seemed to be going according to plan. I popped the master cylinder into place and proceeded to connect up the brake master cylinder's pipes to the bulkhead valve. All looked great. "Excellent" I thought. "Time for the slave cylinder pipe and to connect the new pipe to the master cylinder". Except when I offered everything up, the new slave cylinder pipe was too large for the hole in the bulkhead bracket. I REALLY don't want to remove this bracket again as it'll mean taking out the pedalbox as well as I can barely see the blots with it on. And I don't have a 5/8" drill bit. Arse. I shut the garage door and walked away for a bit. Again.
To cheer myself up I decided to do some Midas paperwork. It's not much, but picture below.
New MCs fit well together. ("Old" new MC has been sold already)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20963_zpsv6hkxbuy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20963_zpsv6hkxbuy.jpg.html)
Hole needs to be this big.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20964_zps7tygtekw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20964_zps7tygtekw.jpg.html)
However, it is this big. Guess what won't fit...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20965_zps9ots3n6f.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20965_zps9ots3n6f.jpg.html)
So I sent this off. Just because.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20966_zpslxnyuue6.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20966_zpslxnyuue6.jpg.html)
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Friggin cars mate. But well done for keeoing at it
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Sorry to see you struggling. It looks like very good progress was being made.
5/8" is very slightly smaller than 16 mm (5 thou). I don't know if you have a 16 mm drill but I would use that without any worries.
I hope you can forgive it and get back to it soon.
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All sorted guys! :laugh:
I have a new toy. It's such a simple idea, which is probably why I didn't think of it in the first place as I always seem to find a more complicated way of doing things. I was browsing the Machine Mart catalogue (always a bad idea as I tend to spend money - and it's on the way home from work if I make a minor detour...) and came across a stepped cone cutter. So, one purchase later and I have easily cut a bigger hole in the aforementioned bracket. It took about 8 seconds to do... As a result I popped on the clutch flexi-pipe and bent the kunifer pipe to shape. It's not perfect, but neither is my paint! As long as it doesn't leak it'll do for me!
New toy. Vicious little nibbly thing too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20967_zpsvprv7nhx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20967_zpsvprv7nhx.jpg.html)
I was able to do this. Me likey.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20968_zps92asnueu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20968_zps92asnueu.jpg.html)
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So I am back from holiday after spending a lot of time in a car the other end of the size scale:
(http://i511.photobucket.com/albums/s353/MrBounce38/DSC_0002_zpsxe42sprt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/DSC_0002_zpsxe42sprt.jpg.html)
Glad I don't have to park that in England - it's a monster! Anyway, back to the smaller things in life. Today was a bit of a "tidying" kind of day in that I spent quite a lot of time underneath the shell with a paintbrush filling orange into all the little bits that the spray gun missed. I didn't bother taking any photos of this as a) it's brush-painted underside of bodywork and b) it's brush-painted so it isn't pretty. Most of it will be hidden anyway... Once I'd finished that I did a few other little bits, the first of which was making sure that the subframe could be bolted in nicely. Firstly I dug out the front mount brackets and spreader plates from the spares box. This was a simple "two bolts and nyloc nuts" job each side, complicated by the fact that the plates and brackets had so much paint on them that the bolts wouldn't push through. I sorted it with a old bolt and a hammer. At least I know they're not going to rust anytime soon...
I followed this up with a trial fit of the tower bolt mounts. I am using solid mounts as I like the idea of a) the better steering feedback and "point-and-squirtability" and b) never having to replace them again. As per usual on this bleeping car, there was a problem. When it was originally built, this Midas had a twin-bolt front subframe from a 60s Cooper S. It was converted to single bolt later, and when the holes were cut for the tower bolts, they presumably only had access to standard rubber mounts. These of course are flexible whereas the solid mounts are not, and the raised section on the mounts sat on top of the edge of the hole. There was just under 1/4" difference. My funky new cone cutters were not big enough, but because it's fibreglass, it's easy to re-shape. Out came my old friend the Dremel with a sanding band on it, and five minutes each side top and bottom saw the mounts fit snugly in place. Perfect. I also took the time to clean up and paint the large washers on the tower bolts as they looked a bit rusty and rubbish. I am unsure about painting the solid mounts as I don't know if the anodised finish is any good or not. Think I will leave them out for a few weeks and make a decision from there.
I have also made a captive nut plate for the wiper motor. I hated the way that mine was previously held on with big self-tapping screws - so I decided to do a bit better. Once the paint's dry I will drill the holes and fibreglass it into place.
Front mount plates in place.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20969_zpsoxfi0peq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20969_zpsoxfi0peq.jpg.html)
Tower bolt hole midway through enlargement.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20970_zpskidqca43.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20970_zpskidqca43.jpg.html)
Mount now fits snugly in place.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20971_zpszqqrl65x.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20971_zpszqqrl65x.jpg.html)
Tower Bolt washers looking more presentable.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20972_zpskyvjowmx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20972_zpskyvjowmx.jpg.html)
And captive nut plate for the wiper motor ready to go on the car.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20974_zpsabwazdpy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20974_zpsabwazdpy.jpg.html)
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It has been a frustrating time - mainly because my garage is in an utter state. I bought a couple of cabinets with plastic drawers at a boot sale last weekend and have been cleaning them and sorting out places for them to go. This meant moving lots of stuff, and so far I have only managed to move it from one side to another... I need to get rid of the fridge in the garage but of course that doesn't fit in a Bora's boot. So of course that means roping in friends - and only one has an estate car...
As such I have got very little done. I have however, revised the way that the battery clamp works on this car. Originally it had a hideous chunk of angle iron with a "T" piece that was screwed into the bulkhead buttress using self-tappers. I have instead used a proper battery clamp (cut down slightly) and have made an "L" shaped bracket which bolts through the bulkhead behind where the battery sits. My battery box had been modified (badly), presumably to allow fitment of a standard Mini battery, so I have used a dead one of these to line stuff up. I have used a couple of spacers between the bracket and bulkhead due to clearance issues but once I used these, it works very well, using the standard "tent-peg" arrangement. Hopefully there'll be a bigger and more exciting update soon.
Bracket spaced out (nuts used as spacers in this pic were just for size purposes).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20975_zpswrdwocwg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20975_zpswrdwocwg.jpg.html)
And the clamp in all its glory. If I am being slightly OCD, it does make the battery sit oh-so-slightly diagonally, but hey - it works and nothing else is going there...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20976_zpsqzhfh1d2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20976_zpsqzhfh1d2.jpg.html)
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Updates an update. Good work though bud
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Big update time!
I decided that I was going to pop the steering column in, and if I was going to do that it was probably a good idea to pop the clevis pins and split pins in to connect the pedals to the master cylinders. You're all probably going to hate me when I say this, but I found it a piece of cake - presumably because everything is stripped out the car. Split pin 1 (Clutch) took 1 1/2 minutes. Split pin 2 took less than 5 minutes and both involved me folding my chunky frame in and out of the car (no easy task).
Right - now that bit was out of the way, I needed to do a few modifications to ensure fitting the column was a breeze. My Midas was different to a Mini in that it had two "cotton reel" spacers which mounted to the bracket on the column. The original bolts that I had was cut off as they were so rusty. I had some spare bolts, but they were too long and the thread did not reach far enough up the shaft. No problem - out came my tap & die set and Harry Hacksaw, and two suitable bolts were created. I was also unhappy with just bolting straight through the fibreglass, so I found some 3mm steel plate in the garage and cut it to shape and drilled some holes. Viola! One spreader plate. I then cleaned it and painted it. Whilst I had the grinder out I also modified the bottom of the brake master cylinder. The pedal box is for a single-line system, and the studs are shorter, meaning I could barely get a nut on to mount it. I gave the "foot" a tickle with the grinder which improved matters no end.
Whilst I was fiddling about by the master cylinders I figured it would be a good idea to redrill the hole for the throttle cable (the old one is now covered by the brake valve). So I did that and also popped in a grommet. Should be nice and straightforward now when I come to fitting the cable.
Fitting the steering column was actually pretty straightforward thanks to the prep work I'd already done. Spreader plate went on first, then I loosened the bolts holding the steering rack on so it could be moved where necessary. On went the column and after a bit of fiddling the pinch bolt slotted into place. A bit more careful lining up and the bolts went through the cotton reels and mount before being tightened up. I re-tightened the rack nuts before I forgot. Then I couldn't resist popping the steering wheel on for a quick look. Awesome day.
Column - you're going on the car matey...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20977_zpsgmk5hxjq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20977_zpsgmk5hxjq.jpg.html)
"Cotton reels" and newly created bolts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20978_zpsk6ozkmqb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20978_zpsk6ozkmqb.jpg.html)
Spreader plate created
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20979_zpsefebkxv1.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20979_zpsefebkxv1.jpg.html)
Modification to brake master cylinder "foot".
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20980_zpsvjozdmmj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20980_zpsvjozdmmj.jpg.html)
Throttle cable bracket fitted
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20981_zpsuv5rb9wb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20981_zpsuv5rb9wb.jpg.html)
Column in place
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20982_zpssrbyycgp.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20982_zpssrbyycgp.jpg.html)
And just because I couldn't resist!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20983_zpswoeevbph.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20983_zpswoeevbph.jpg.html)
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Is that actually a mutiny stearing wheel.or just a universal one with that button?
Good work so far
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It's a Mountney that I bought from someone on the Mini Forum. I did need to get a boss for it though.
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Thats what I ment. Mutiny and s a bmx brand.
Ive got one on a mini boss that I need to get a different boss for. Just noticed the m sybol
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Looking good bud. :)
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Just a quick update this evening. Once again I have been far too busy on other stuff so have left precious little time in the garage. However, have done a bit as Andy has been round to help out. I have the front subframe fitted loosely with mounts ready to fit (no pics) but this evening we turned our attention to the rear end. Typically for me, I had built up the full rear beam including radius arms without looking at the pictures taken when I took it apart. There was no way in hell that the bolts on the edges would go through with the radius arms in place... No bother - as the thing was on the bench anyway, out came the spanners and the two of us had the arm off within 5 minutes.
We then did a trial fit of everything then we bolted the beam to the car. I remember reading somewhere that the Mk 1s & 2s are ever so slightly different from side to side (can't quite remember why) and the bottom bolt on the nearside is right next to the bodywork. This meant modifying the washer - I remember the one I took off having about 1/4" taken off one side - so out came the grinder and I gave the washer a little tickle until it fitted perfectly.
I should stress that the beam is only on temporarily. I am not happy with the fit of the fuel pipe (bends are in slightly the wrong place) so will whip the beam off again next week and sort the fuel pipe before refitting everything properly. Who knows - there might even be wheels attached next time...
That's a rear beam - attached to my car!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20984_zps0km1ensq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20984_zps0km1ensq.jpg.html)
Modified washer on lower bolt so it will actually fit! (Apologies for poor focussing...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20985_zpsne2cwhiu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20985_zpsne2cwhiu.jpg.html)
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Right now I am an angry man. I am not sure exactly who to aim my anger at though. Let me explain: when I started on the rebuild for this car, I decided to use dual circuit Mini brakes using a "yellow tag" master cylinder and brake limiter valve on the bulkhead. I had used this set-up on 3 of my old Minis and they all had very good brakes - it just seemed a better and more cost effective idea to do this than buying a brand new Cooper S master cylinder and rear valve which would have cost £150. Of course, the main problem I had was that I needed new brake lines - not a problem as I was going to replace them anyway. And this is where the problem starts - BL or Austin Rover or whatever they were called that week thought it would obviously be a really good idea to have the two different ends of the brake pipe with different threads, one UNF, one metric. And obviously they were going to make it where one would fit the other, but only for a couple of turns - and it won't tighten up. However, for some reason, there is also an all metric brake line available (I know that Mini Sport sell one - https://www.minisport.com/bp96m-brake-pipe-96-front-pressure-valve-to-rear-3-way.html?___SID=U ). I have just discovered this, as the one I have fits perfectly in the valve on the bulkhead, but at the rear, it won't go in to the UNF 3-way union at all. I think that I have been accidentally sold an all-metric pipe because before I fitted it, I only checked the fit on the valve. More fool me. My problem is, I can't remember where I bought the pipe from so I can't yell at anyone but myself.
Therefore I will now have to remove the whole pipe and replace it with the correct one unless anyone knows where I can get a 3-way union with a metric inlet and two UNF outlets? This will take an annoying amount of time and will also require the help of an assistant, to hold a screwdriver so I can undo the bolts for the P clips. I am hoping that I can squeeze the new line in without having to fully remove the rear beam because...
I have re-done the fuel line, and it was a good idea that I did - I found a kink in the last 3 inches, which would have made fuel delivery a touch restricted. I cut the kinky bit off and it now sits nicely over the top of the beam, ready to be connected up to the fuel pump and filter I have. I have also fitted the first of the two radius arms. Using the help of a conveniently sized wooden box, which was exactly the right height to rest the arm on, I was able to attach the arm and associated bracket and tighten up the the nuts. I also chucked on one of the beautiful new rear shocks. However, I couldn't fit this properly, as when I jack the arm up, it'll only go so far before the rest of the car comes with it - this means that with the new bushes I can't get the top nut on it... Damn you new springs!!
More to follow as long as I don't go in there with hammers.
Fuel line now going exactly where it should be.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20986_zpsbilnogck.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20986_zpsbilnogck.jpg.html)
Radius arm attached to car, complete with backplace and brake mechanism.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20987_zps4ihrrl9x.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20987_zps4ihrrl9x.jpg.html)
Oh, and one of these beautiful bits of kit too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20988_zpszbjf0oem.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20988_zpszbjf0oem.jpg.html)
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I have come very close to setting the garage on fire this weekend. I don't know whether it's me doing things wrong, or if this car is cursed, or I have just been REALLY unlucky with items bought.
I have firstly dealt with the brake pipe issue by getting myself a brake flaring tool, along with a proper pipe cutter. I tidied up the fuel pipe end whilst I was under the car using said cutter, then removed the offending metric brake union. A small bit of work later and I have a re-flared pipe end with the proper UNF union on it. Then Andy popped round on Saturday and after a bit of cursing and hitting things with a rubber mallet, the second radius arm was on the car. I haven't properly tightened up the nuts on the brackets yet but that will come later. On went the shock and we connected both shocks up without the top bushes in for now, until we can lower the car down onto its wheels. Then it all went a bit pear-shaped.
The plan was to pop the drums on and sling a couple of wheels on and take the thing off the rear axle stands. I wound the adjuster all the way out so the shoes were at their lowest possible adjustment. From what I can tell the springs and shoes are all in the correct position. But the drums will not go on. I took the whole brake assembly off and tried the drum on with it missing. Drum goes on ok. Put everything back on. Drum won't go past the shoes.
I have shut the garage and walked away, making sure that in the meantime I have no access to anything that can produce flame or be used as a clouting tool. I shall return to the garage when I am in a better mood...
Brake Pipe Flaring Tool helped sort out my pipe problems.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20989_zpsezz9sdbn.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20989_zpsezz9sdbn.jpg.html)
Driver's side radius arm now on.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20990_zpshc3zkpvt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20990_zpshc3zkpvt.jpg.html)
Look at the shiny shiny (which won't go on...)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20991_zpsicqkasd0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20991_zpsicqkasd0.jpg.html)
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Another quick update as there's not much to show for it - but I have managed to sort my shoes & drums issue. As I had bought the shoes from a show many moons ago, I have no idea a) who I bought them from and b) who made them. So I did the honourable thing and bought myself a set of Mintex shoes from our local Mini Specialist. Today I went into the garage and after the usual swearing and struggling with those pesky brake springs, the shoes were on.
Now it was time to answer that million-pound question - would the drums go on? As I am not currently sitting in a police cell for arson, you know it did without a hitch. It's a funny old world. (*Note to self - don't buy no-name parts from a show...)
The answer to the brake shoe issue: Mintex shoes!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20992_zpsxr6sgsed.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20992_zpsxr6sgsed.jpg.html)
And look - it fits!!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20993_zpsf3dapsup.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20993_zpsf3dapsup.jpg.html)
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Just in case you all thought I'd given up and gone away, don't worry - I am still here - there just isn't a huge amount to show for my recent couple of evenings in the Manroom. My main reason for this is Mini rear brakes. I never liked them much in the first place, but this is the first time I have taken a set totally to bits and put them back together again.
Firstly we had the issue with the unusual brake shoes where the drums would not fit over them. They were cheap and from a show and clearly didn't fit properly. A comparison with my newly acquired Mintex shoes showed that despite having all the same fixtures, holes etc, the cheapo shoes had a shedload more meat on them, but more importantly, the curve of the metal part of the shoe was totally out of true. Lesson learnt: buy cheap, buy twice. Unless anyone wants them for free, they're going in the bin.
Secondly is totally down my own stinking incompetence. Like I said before, I had never had a rear brake set totally in bits before, so when I built them up I was delighted to get the shoes and springs on correctly and lined up nicely. The only problem was that Mr Numpty here had conveniently left off the handbrake mechanism, so I had to take them all apart again, find and then fit the handbrake levers and gaitors before re-fitting the shoes.
There was much shouting, swearing, springs sprung somewhere in the Manroom and bleeding fingers, but eventually, both sides now are in place. No pics as I did not take the camera in with me.
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Right - having been having a clear-up and building a tool wall for the garage, I am now back on the project again.
As I am likely to fitting stuff back together in the coming months, and there's a few bits already on the car that are rear brake-related, I pulled the handbrake mechanism out of the bits box. I gave it a clean up and followed this up with a coat of paint. It needs greasing up before fitting but I will get round to it once I have drilled the mounting holes for the new handbrake lever - the old one was scrap so I will be using a Mini lever I bought AGES ago.
And now - for some slightly bigger news: The front subframe is ON. Andy came over last night so I fed him then put the boy to work. Using a large piece of wood and a jack, we lifted the subframe up as far as it would go, only to find that the front teardrop mounts would not fit past the front panel. We played around for a bit, took the teardrops off and wound the tower bolts in slightly so we could (with the use of the "F" crowbar) make enough room to bolt the teardrops back in. This meant we could wiggle everything into position so it looked almost ready to go. Then of course there was the heelboard mounts. The passenger side needed just a little tweak with a screwdriver to pull in into line and the bolts lined up beautifully. We got the nuts on but left them loose in case of further tweaking. The driver's side was somewhat more swear-worthy. It took a good half an hour's worth of extremely bad language, struggling with lining things up and dropping stuff before it all fitted together as it should. I still don't know where that nut and washer went mind you...
The front teardrop mounts will need a bit of work though. The Mk1 front end is different to the Mk2 and this car also originally had a twin-bolt subframe in it when it was first built. I have had a look through my old photos and when I took the subframe out there was an extra nut in front of the teardrop mounts acting as a spacer. As I am using solid mounts, I will get proper spacers made up to fill the gap. More soon!
Handbrake gubbins loosely fitted together.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20994_zpszuhe5tm0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20994_zpszuhe5tm0.jpg.html)
There's a subframe fitted to my car!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20995_zpshuzxrsha.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20995_zpshuzxrsha.jpg.html)
Some minor tweaking and spacers are required at the front.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20996_zpssk8oihfe.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20996_zpssk8oihfe.jpg.html)
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Just a very quick update - I was round at Tink's last night and asked if he had any spacers kicking around. Out came a whole box of them. I found two nice round ones in aluminium although they were a bit thick at 14mm. I shortened them to 9.5mm and they fitted beautifully. All is nipped up nice and tight as a solid mount should be.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20997_zpsi3ln8hb5.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20997_zpsi3ln8hb5.jpg.html)
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I haven't done a huge amount on the car recently, mainly because I was looking for a specific bit in the garage. And of course this bit was in the last place I expected to find it - as such it took AGES to find. Still, the Manroom is a little bit clearer now...
I had an issue. When putting some stuff on the bench the other evening, I happened to knock one of the light lenses off, which hit the floor and broke. I have managed to find another on eBay (the correct side too - I did check!). I have glued the old one, but if it doesn't take I will still have the new one to help. Still, it's a pain in the **** that I could have done without.
As I am still concentrating on the rear end, I needed to sort the handbrake itself. The one in the car was of unknown origin, but was also knackered, with its button and internals either missing, seized or broken. So I got myself a standard Mini handbrake. This of course did not fit at all due to the Midas tunnel having no appropriate bracketry to mount it too. The Midas handbrake had horizontal mounts, whereas the Mini item's were vertical. Not helpful. Still, I am nothing if not resourceful. I had knocked up a bracket & spacer arrangement a couple of years ago but needed a half decent spacer to replace the hacked about steering drop bracket I'd used as a temporary measure. Once again Tink's spacer box helped, offering a perfectly sized item. I shall drill the holes in due course and mount it.
Moving on, I FINALLY found the bits I had been searching for: seatbelt stalk mount captive nut plates. I had put these in the cooling system parts box so I wouldn't lose them. It took the best part of 5 hours' searching to eventually unearth them. Luckily they'd already been reconditioned and painted. As I was on my own in the garage and don't have arms like Mr Tickle, actually getting them in place provided a slight issue. This was solved by popping the bolt through the bodywork, securing it with a ratchet & socket, then spinning the plate on until the rivet hole lined up. I then chucked a screwdriver through the hole and tightened up the bolt. This kept the rivet hole lined up nicely. I then simply removed the screwdriver and used a 16mm headed rivet to secure the plate. I also drilled a couple of extra holes in the plates to double up on the rivets. I still need to drill the new holes. Still , the first one is mounted with (the original arrangement of) one rivet. I ran out of time to do both (Took Mrs B out for her first drive of my daily) so will sort the other one next time.
Not the sort of thing you want to happen. I swore. Loudly.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20998_zpsf5cednyo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20998_zpsf5cednyo.jpg.html)
Handbrake with better looking spacer (awaiting paint).
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%20999_zpsijznvpmn.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%20999_zpsijznvpmn.jpg.html)
Been looking for these for AGES!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201000_zps2fihiod8.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201000_zps2fihiod8.jpg.html)
Riveted in place.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201001_zpsvsgtvyyn.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201001_zpsvsgtvyyn.jpg.html)
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Got a bit more done tonight, and as usual I ran into a setback or two.
I fitted the second seatbelt stalk captive plate. Having done one already, this was a piece of cake and only took a couple of minutes.
I gave my washer bottle a good wash - this included the cap, the plastic thread in the cap and the plastic gauze filter in the filler neck. This had accumulated all sorts of dirt and stuff during its time in storage including what looked like the remains of spider's eggs. A few minutes with some bleach and judicious use of a scrubbing brush had everything looking much cleaner. By the looks of things, the bottle itself either began with a blue-ish tinge, or the number of years that it's had screenwash in it has permanently stained it.
I then turned my attention to the wiper motor as this will probably go in the car soon, mainly to get it out of the way as it's not the easiest thing to store. I firstly looked at the wheelboxes and the outer rack tubing. This was covered in surface rust following my rust removal back when I'd first removed it. I will clean this up and respray it. However, when I originally cleaned it, I did not take the wheelboxes apart, and they're really stiff and covered in solidified old grease. Time for a dunk in the parts washer and a re-fresh.
Whilst working on the wiper bits, I decided that the best way to get rid of the hubs that I kept having to move was to put them on the car. I would have also connected up the steering rack but then I realised that I didn't have any locknuts for the track rod ends. These will need to wait until another day. The hubs themselves are just finger tight at the moment as I will doubtless need to pop a balljoint or two to get the engine & driveshafts in.
Finally I checked the glued-together lens. Typically some glue has seeped out on the outside. I might be able to save this by some careful Dremel work, but as there's another one coming it'll be good for a spare if nothing else.
Seatbelt stalk mount in place. Significantly easier than the first one... (Excuse the rubbish pic)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201003_zps4od4gmzf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201003_zps4od4gmzf.jpg.html)
Funky washer bottle now devoid of spider eggs and looking clean again. Made by Mitsubishi.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201002_zpsxqgq9viz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201002_zpsxqgq9viz.jpg.html)
Wheelboxes look nasty. Time for a Parts Washer dunking.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201005_zpslg97f2ii.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201005_zpslg97f2ii.jpg.html)
Hubs on (albeit only loosely)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201004_zpslkllyupw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201004_zpslkllyupw.jpg.html)
It's just a little seepage! (Hopefully the Dremel can clear it up)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201006_zpspgaaesnh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201006_zpspgaaesnh.jpg.html)
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Nearly back together isnt it?
Looking excellent though
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Good to see your progress on this.
A freshly sharpened chisel might be a better tool to start with on that glue than a dremel. A slight slip will cause less damage and the results will be more "optical".
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These last few days have seen a lot of me wondering "Where on earth have I left my head?" with a smattering of "When is it actually going to go right?" As I am nearing the time to put the hubs, flanges and driveshafts on, I thought it wise to buy some more hub nuts and conical washers. Once I'd purchased these, I dug out the new CV joints in their (sealed) boxes. In each box was a brand new hub nut and also a conical washer, put there by me. I had then sealed each box so I wouldn't lose them. Nuts - literally. Still, I popped over to Tink's on Thursday and with his assistance & the help of Clyde the club hammer and a block of wood both cv joints were successfully mated with the driveshafts. I will use the new conical washers as one of the originals has some pretty deep marks on it thanks to the previous owner (or the one before him) "undoing" the hub nut using an angle grinder.
Moving onto the flanges, all looked good other than they were filthy. Or so I thought. It appears that I only have 4 of the correct bolts to mate the flange to the disc. So another eBay order has been made. Still, whilst I had them there, I gave them a good dunking in the parts washer. I am undecided as to whether I should paint them or not.
Finally, as I had the parts washer on the bench, in went the wiper wheelboxes. It was halfway through the cleaning that I noticed that there's virtually no thread on them and they're nastily corroded. Time for new ones...
Nice new CV Joints.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201008_zps25fjdk5b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201008_zps25fjdk5b.jpg.html)
This is a picture of a dirty flange (snigger)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201007_zpskr3jf5ch.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201007_zpskr3jf5ch.jpg.html)
Knackered wiper wheelbox (1 of 2)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201009_zpsuweqevtm.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201009_zpsuweqevtm.jpg.html)
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Can the threads not be repaired on that??
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Can the threads not be repaired on that??
Too much material missing... :cry:
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Had a hour or so this afternoon so popped into the Manroom with a view to having a big tidy up and to also start assembling the front end drivetrain. This meant popping the driveshafts on to the car - which was a good plan seeing as I was running out of places to put them - they're not the easiest things to store... I would have then put the flanges and discs on but I decided that the flanges (even once they'd been cleaned) needed some paint. So out came the engine paint and on went some blue. Hopefully the next time I go in there'll be much activity and the front wheels will appear on the car...
Right hub complete with trackrod end and driveshaft...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201010_zps12rxhh48.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201010_zps12rxhh48.jpg.html)
...and the left one too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201011_zpsuoggjebr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201011_zpsuoggjebr.jpg.html)
Flanges left off because I deemed it necessary to give 'em a coat of blue. Nice!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201012_zpsrrgormba.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201012_zpsrrgormba.jpg.html)
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I went into the Manroom this morning armed with the knowledge that I should have no issues putting the flanges and discs on the car and also torqueing up the hub nuts. Amazingly, it all went according to plan. Almost...
First job was to pop the flanges on to the new discs - these were brand new in box, still in their waxed paper, although there had been a minor ingress of dampness. This won't be a worry as it is only a very small amount of surface rust in localised areas. These were bolted to the flanges, then it was time to pop them on to the car. On went the driver's side, and before anything else, I torqued up the flange bolts as it's easier to do them on the car. Then out came the special washer to correctly seat the wheel bearing and cv - once torqued up correctly, it was undone again and the conical washer popped in correctly, re-torqued and in went the split pin after making sure it was all lined up.
All went exactly according to plan on the nearside as well, until I realised that I had a loose wheel stud. So off came the flange and disc, then I removed the offending stud. It didn't look very healthy and had stripped its splines as well as having rubbish threads. Luckily I had a new one so gave it some gentle taps into place and it's now solid as a stud should be. Once everything was back together it was all torqued up and now needs calipers and wheels. Whoop!
Flanges and new discs in lovely waxed paper.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201013_zpsoscolurh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201013_zpsoscolurh.jpg.html)
Discs attached to flanges
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201014_zpsqliclndu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201014_zpsqliclndu.jpg.html)
Hub nut and big washer for seating cv & bearing.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201015_zpsrao19zvp.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201015_zpsrao19zvp.jpg.html)
Driver's side all done and torqued up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201016_zpshn7rfvhd.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201016_zpshn7rfvhd.jpg.html)
Pesky loose stud. It was removed, inspected and unceremoniously binned.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201017_zps3yaxnqx5.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201017_zps3yaxnqx5.jpg.html)
Nearside all fitted and finally sorted (Take 2!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201018_zps5a7lgzcl.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201018_zps5a7lgzcl.jpg.html)
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I loke the blue and would like to see a pic against the orange to see how it looks.
Good work as always mate
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I have come to a fairly big point in this project - and it's one that will free up a nice bit of space in the garage. No, I haven't decided to sell it on - instead it's time to get the engine out from under the bench and chuck it in engine bay. So, using my amazing muscles (and wheezing like an asthmatic 2 stoke), I "walked" it from one end of the garage to the other, managing to avoid coming even close to touching the bodywork. When you consider there's only just enough room to get my chunky frame past, you'll appreciate that this was some feat. Typically though, I have discovered that I have put a 2-inch scratch on the rear 3/4 which WILL need attention. So the spray gun will come out AGAIN when it gets warmer...
I turned my attention to the radiator and how I was going to mount it. The bottom slotted into holes in the valance and a couple of tie-bar bushes fit nicely on the feet and sit in the holes perfectly so I'll be using those. The top however, was a different story. There were 2 "L" shaped brackets on it with captive nuts which weren't fixed to anything so not ideal. Plus I could only find one now, and the large hole to locate the top radiator pin wasn't quite big enough for the new rad. So I thought a bit laterally - rather that bolt through the bodywork, which I REALLY didn't like the idea of, I could use a similarly sized bracket and build up the fibreglass where it would need to sit before drilling it and popping in a rivnut. It won't be under a huge amount of pressure so should be plenty strong enough. And that way it can be easily removed whilst also negating the need to drill through the existing bodywork. This made me happy.
So I set about the old bracket with the cone cutter, Clyde the Club Hammer and the angry grinder, then made a rough copy using an old "Ultimate Engine Steady" I had kicking about. They're a bit ragged to start with, but they won't be seen and I intend on cleaning them up a bit before painting and fitting properly. I chucked a couple of grommets in and they fit beautifully. Now all I had to do was to build up the bodywork with fibreglass by about 5mm. So I contorted myself into the engine bay and spent the next half an hour cutting, mixing and dabbing until I had a mound of fibreglass that looked like an oversized teenage zit. I will drill it and fit the rivnut once it's dried out. I've only done one side so far but I should be able to get in from the top once the engine's in. I hope...
The Engine. It's a bit dusty, but I can clean it. Oil Cooler removed for now so it will be easier to fit in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201019_zpswzkazq8w.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201019_zpswzkazq8w.jpg.html)
Original (but re-purposed) bracket to mount the top of the radiator to the side of the engine bay.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201020_zpszjnfq8di.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201020_zpszjnfq8di.jpg.html)
And the one I made from the old Ultimate Engine Steady. Tidying up still to do...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201021_zpsprcbia1h.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201021_zpsprcbia1h.jpg.html)
Built up fibreglass looking like a zit! :laugh:
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201022_zpscddatavx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201022_zpscddatavx.jpg.html)
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Today, Shaun was over early, so we got cracking after some bacon sarnies. Armed with a good sized engine crane, some rope and some ingenuity, it was time to fill the big hole in the engine bay. Firstly, we needed to move the axle stands from under the floor to subframe so we could get the front of the car to a low enough height. This proved extremely easy. We wrapped a big ratchet strap around the front subframe and lifted the body up using the engine crane. Moving the axle stands was a piece of cake and no need for the jack. Once the stands were in place, I cracked the top ball joints to make the pot joints easily manoeuvrable whilst Shaun wrapped the rope around the engine and clipped it to the hook on the hoist. 10 seconds later the engine was in the air. It was at this point I chucked on the speedo cable.
I have read numerous different reports on how the engine is put into a Midas, but as I did not have the ability to raise it up with the subframe, it would have to be in through the top. I had no idea whether it would fit or not, so simply went for it on a "suck it and see" basis. First thing is first - the design of the bonnet is a pain in the ****. The "wok" end plate with its casting for the starter motor will NOT fit. So off this came. It then became quickly apparent that the clutch pressure plate would also be in the way. More spannering. Finally an extra bit of necessary clearance was found by taking of the nearside engine mount too. So, I was putting in an engine with no engine mounts and half a clutch. Good start...
However, this wasn't too much of a problem. Once we had swung the engine to a strange angle (i.e tipped back by 30 degrees and almost diagonally across the engine bay), we were able to drop the main extremes below the bonnet line. Now all I needed to do was put the clutch pressure plate back on, along with the wok and the nearside engine mount. Once we'd done this, in went the pot joints (surprisingly easy) and then it was time to sort the bolts for the engine mounts. I had made my own captive nut mounts by getting a pair of captive nut mounts from a Mini show, cutting off the really rubbish "nuts" and replacing them with some properly welded UNF nuts. Offside took 35 seconds to get in. Typically the nearside then took about 35 minutes as they just refused to line up. Eventually all was in and there was an engine in my car!
Need to move axle stands? No problem - just lift the car!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201023_zpsciyoycgt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201023_zpsciyoycgt.jpg.html)
Engine up in the air...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201024_zpsghmyk1tb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201024_zpsghmyk1tb.jpg.html)
Speedo Cable. Glad I didn't forget this...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201025_zpsujt6cg57.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201025_zpsujt6cg57.jpg.html)
We have clearance, Clarence (not by much!)
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201026_zps3z8p1iqj.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201026_zps3z8p1iqj.jpg.html)
Almost there - time to start bolting bits back on...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201027_zpsbrwjuuk3.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201027_zpsbrwjuuk3.jpg.html)
Looks right at home doesn't it?
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201028_zps4ypgefbi.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201028_zps4ypgefbi.jpg.html)
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Love reading your updates :cool:
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Love reading your updates :cool:
Me too.
The engine looks awesome sitting in there.
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Cheers guys! Means a lot :cool:
Not a huge update as I have had a lot on this week. Grabbed a quick hour today and managed to bolt on one beautiful brand new damper, then turned my attention to the radiator mounts I'd knocked up. one of them was a re-used and re-bent bracket that was once attached to the original radiator. This looked a) a bit rubbish, and b) had a huge fatigue point on it where I'd bent it back the other way. This was proved to be a weak point when I knocked the radiator over and it landed on the bracket. It snapped, not entirely unexpectedly.
However, as this was only meant to be a mock up anyway, I grabbed the remains of the old Ultimate Engine Steady I had kicking around and fired up the angry grinder. A brand new cutting disc made short work of the thick steel, then it went under the pillar drill to get a suitably-sized hole or two made. Once this was done I chucked it in the vice and attacked it with a blowtorch until suitably warm, then clouted it with Clyde the Club Hammer until bent to shape. It's now hanging up with its brother having had a coat of primer before paint. More soon.
Brand new sparkly damper. Yeah.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201029_zpswalwf3bf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201029_zpswalwf3bf.jpg.html)
Radiator brackets (including new one) now in primer.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201030_zpswbgtkiwc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201030_zpswbgtkiwc.jpg.html)
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Time for another quick update. I started to clear the main workbench as it had got a bit messy. Pulled out the heater as I had managed to get some overspray on it. Stripped it down and gave the outer panels a fresh coat of satin black. Then, as I was sorting other stuff out, I found a piece of scrap metal I thought that I had lost or thrown away. "That'll do for a bracket for the solenoid" I thought. So I dug out the solenoid, took it out of its box and started mocking up with good old CAD (This time it was the cardboard packaging for a new pack of socks!). If your starter is the older type with no piggy-back solenoid, you need to find somewhere other than the inner wing for the solenoid to sit as of course there's precious little in the way of inner wings on a Midas...
Once happy with the mock-up, out came the angry grinder and I used a 1mm cutting disc to make mincemeat of the now marked piece of 3mm steel. I cleaned the edges up with a file, then set about measuring then drilling a few holes for mountings. It's going to live on the front of the clutch cover above the starter, so all I needed were 4 simple holes and judicious use of a blowtorch and hammer. Over to the pillar drill, then I marked it, heated it with the blowtorch for a good few minutes then clouted it hard with a hammer until it was the right shape. In went a couple of 5mm rivnuts and I tested out where it's going to sit. It'll still need a little bit of trimming but overall I am happy with it.
CAD Template
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201031_zpsjucwql66.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201031_zpsjucwql66.jpg.html)
After bending and rivnutting
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201032_zpsqmddlno2.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201032_zpsqmddlno2.jpg.html)
Fitted. Still needs a bit of trimming but fits pretty nicely.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201033_zpsdr4fiscu.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201033_zpsdr4fiscu.jpg.html)
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Back on it tonight after a hectic long weekend, I sneaked into the Manroom this evening to get an hour or so's worth of tinkering. I'd chopped a a couple of bits off the solenoid bracket to avoid losing a hand whenever I went under the bonnet and had also painted it, so I then chucked it on the engine to get it out of the way. When i was looking at the engine I thought I'd try the steady bar. Of course, this was a stupid idea as a) you need a shorter one in a Midas and b) there was a clunk and the metallic "clink" of something hitting the floor as I pushed the bolt through the bracket. Yup, the washer that had been welded or brazed on had gone walkabout, leaving a larger hole. How helpful.
I remember when I first added this bracket thinking that I was glad I would never have to fit it again. That of course was without the pedals and clutch lines added. Now of course, it was the most difficult thing in the world to remove. As the pedals are in the way you cannot get a socket on the bolts. The only option is to jam a spanner in there and hope for the best. After 20 minutes of adding to the swear box, off it came. Then off to the bench to give it a quick strip with the angry grinder and wire wheel and then find suitable washers to weld on properly. I will be taking it to Tink's tomorrow to use his ridiculously good MIG then will give it a fresh coat of satin black. It's likely I will then spend 3 days trying to put it back on...
To stop myself getting too annoyed I chucked in the heater brackets under the dash shelf so when I get some more time I will be able to add said heater to the car and get it out of the way. And finally I started making a CAD template for the expansion tank, which will hopefully sit on the crossmember just in front of the washer bottle.
Solenoid bracket amended to make it less lethal to hands...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201034_zpsw01ziaiw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201034_zpsw01ziaiw.jpg.html)
The most awkward thing to remove in my car. This includes the M/C split pins. Viewed from above to amuse you.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201035_zpss020s97o.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201035_zpss020s97o.jpg.html)
This is the reason why - there used to be a washer here, making a smaller hole for the bolt.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201036_zpsytu3bgwx.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201036_zpsytu3bgwx.jpg.html)
Bracket stripped of paint and washers ready to be welded.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201037_zpszumnazyo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201037_zpszumnazyo.jpg.html)
CAD Template started for expansion tank. I need to find something appropriate to cut up for the bracket now...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201038_zpsfm5ohhfr.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201038_zpsfm5ohhfr.jpg.html)
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You know those days where everything goes a bit wrong? I appear to have been having one for the last 3 days it would seem. Firstly my welded washer came off my steady bar mount so I took it to Tink's to use his welder. He discovered that he was out of gas. So he kindly took it to work and got it sorted there and I picked it up this morning. I then primed and painted it, running out of primer at just the wrong moment... Once the paint was dry I set about putting the mounting back on the car with a view to nipping up the new adjustable steady bar (also painted).
Amazingly, given my recent luck, the mount went back on the car really easily although of course I scratched the newly painted steady bar. I made up a spacer for the mount and bolted it all together. I then went to line it up with the engine and found that the steady bar was almost an inch too high. I suppose that nothing should surprise me on this car given the number of bodges I've encountered, but the steady mount is THAT far out?? Of course it may never have been used as there was a "Heath-Robinson" effort on the thermostat side of the engine (which looked about as effective as using Play-Doh...), but surely it doesn't take much to measure something properly?? Maybe I should have checked it first, but you wouldn't expect a mounting point to be that far out.
I shall use my CAD template skills (still in their infancy) and will make a new bracket up that utilises the original mounting points so I don't have to "drill and fill". That is, once I have stopped wanting to find the man who put it there in the first place and subject him to something severe. And possible painful...
Repaired bracket and new steady bar, both wearing new paint.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201039_zpshmfdkgu9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201039_zpshmfdkgu9.jpg.html)
It should be about an inch lower. Must resist the temptation to grab hammers and get ugly...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201040_zpshq61zqth.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201040_zpshq61zqth.jpg.html)
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Having not gone into the Manroom for a week, I returned the other day realising that, in no uncertain terms, I have been an idiot. My apologies to the man who made the steady bar bracket. If I hadn't been so grumpy and tired I probably would have tried a different way of attaching the steady bar - this was, quite simply, to attach it to the engine first (loosely) and simply raise it up to fit the bracket correctly. All is now attached at the top, so I moved on to the other steadies.
I don't like the "Ultimate Engine Steady" bars that are offered on the Mini market having had a bad experience myself, so I looked into other ways to keep the engine in place. The older Minis of course never had a problem with the enormous aluminum gearbox extension on the remote boxes, but having a newer rod change box meant this wasn't an option. The standard set-up is of course the top steady bar from the bulkhead to the engine, and the one from the front of the gearbox to the subframe. Then there's the option of the "Ultimates" which I didn't want, but there are also the bottom rear steady bars available from Mini Spares. I had bought these ages ago so got them out of the cupboard and set about fitting them. The front one was a piece of cake, as was the left hand rear one - simply bolt up and forget. The right hand rear one just required one extra hole drilling in the subframe - not the easiest angle to get to. However, once the hole was there it was nice and simple. The engine doesn't move at all now - job done.
Continuing the theme under the car, I figured I may as well attach the gear selector too. Now bear in mind that when I got the car, it had no engine and gearbox in it, and the previous engine had been a Cooper S engine complete with remote box. As a result the gear selector hole was in the wrong place. I had filled in the hole with fresh fibreglass a couple of years ago, and now it was time to a) drill the holes for the bobbins and b) cut a big hole in the floor.
I don't know it different Midas models came with different transmission tunnels (or whether they could be ordered with different ones according to gearbox type, but it's clear that mine was designed for a remote box as it's far more curved. However, I drilled the holes (twice it turned out due to the curve - the unused ones are now grommeted up) and managed to get it all mounted. Amazingly I got the roll-pin in first time (yes, I did make a smug face underneath the car) - now all I needed to do was to cut a hole. So, using the mounting plate for the gaiter as a template, I marked out roughly where to cut, and attacked it with the angry grinder and the Dremel. It still needs a bit of tidying up, but I am happy that it's now done.
Finally I turned my attention to the engine and popped the oil pressure light switch in as well as the sender unit for the electric gauge I have. There's not a lot of clearance in there at all, so I may change my plans to just use the gauge. I shall consult various experts and see what they suggest.
Top steady bar now fitted after previous idiocy.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201041_zpszvf4d4bw.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201041_zpszvf4d4bw.jpg.html)
Bottom front bar fitted as well
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201042_zpsmmjpgd1q.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201042_zpsmmjpgd1q.jpg.html)
Left rear...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201043_zpswc9qmnbe.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201043_zpswc9qmnbe.jpg.html)
...and right rear all bolted up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201044_zpshbttye15.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201044_zpshbttye15.jpg.html)
Extended gear selector also fitted and bolted up.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201045_zpscw8p1qzp.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201045_zpscw8p1qzp.jpg.html)
Template marked out for making a hole...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201046_zps8fmfrckc.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201046_zps8fmfrckc.jpg.html)
There's a hole in my car. Selector taped up to avoid filling it with fibreglass dust.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201047_zpsjohdtfdv.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201047_zpsjohdtfdv.jpg.html)
Thick fibreglass in this bit, thankfully.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201048_zpsnrvm2fda.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201048_zpsnrvm2fda.jpg.html)
Not much room for the oil senders. I am thinking of changing my plans - nothing is set in stone.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201049_zpsseoz5knh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201049_zpsseoz5knh.jpg.html)
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Just a quick update tonight, but it is another successful one. A few months ago, when I'd fitted the tank sender unit, one of the bolts didn't nip up properly and I made a mental note to check it out. When I had a tidy up in the garage, I moved the tank and had a look at it. Turns out that, despite me using new bolts from Mini Spares, the threads had stripped. The tank itself was bought secondhand, so my guess is that someone had re-tapped the bolt holes. Either that or they were all knackered.
This left me with a number of options. 1) Throw the tank away and buy a new one. I really didn't fancy the idea of spending £150+ on a new tank that I would then cut the filler neck off a bit. Plus I didn't have £150 spare. 2) Chop the offending area out and fabricate a new bit and weld it in. Both mine & friend's welders are out of gas. Plus I would not be sure how successful it would be. 3) Drill and re-tap the offending knackered holes to a larger size. Armed with encouragement from 2 very helpful Mini Forum members, out came a 4mm drill bit, which was followed by the hoover and then an M5 tap. I did need to make the holes in the gasket slightly larger (using a belt punch of all things!) but it all went together surprisingly well. The acid test came when I'd put it all together - would it leak? 5 minutes with a litre or so of fuel with the tank on its side said no. Success! And a happy me with more in the bank!
Stripped threads on new bolts.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201050_zps94tvohte.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201050_zps94tvohte.jpg.html)
Larger M5 bolts make a good seal. Lovely.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201051_zpsruoqab9q.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201051_zpsruoqab9q.jpg.html)
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Apologies for the somewhat glacial pace of this rebuild - things like work and family seem to get in the way, which is a little unfair really! Anyway, after a trip down to Brighton to see all the Minis and the stalls, I came back with a few bits and have done a few minor things and come across yet ANOTHER problem. I shall explain:
I got some more blue paint and have given the tank a decent covering of it as the black I'd hit it with was a bit rubbish. So all I need to do with it now is to pop a new seal on to the sender (the old one looked ropey) and chuck it on the car, which will help me with determining where to put the fuel pump. I managed to pick up up various bits in Brighton, including new wiper wheelboxes, a dipstick which (almost) matches the engine and a new alternator, as when we tested it, my current one doesn't do as it's supposed to.
The calipers were ready to go on, so first of all I found my fresh set of EBC Black stuff pads, new pins and anti rattle shims, then built them up on the bench and after remembering the copper washers, put them on the car. It will soon be time to put poor Zippy back on his wheels and move him out into the daylight so I can have a good look at what needs to be sorted. There's numerous little scrapes and chips on the fresh paint (all my fault) so I will be needing to do some touching in. Oh joy - more painting...
Finally I have discovered my latest problem: My beautiful MG Metro rocker cover with its new cap does not fit under the bonnet. There's precious little room under there anyway, but the cap and the t-bars foul, so unless anyone can suggest an alternative oil cap that fits in the MG cover, then a different original-style cover it is. Balls.
Freshly painted tank - soon to be added to the car.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201052_zpshj678ums.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201052_zpshj678ums.jpg.html)
New wiper wheelboxes. The old ones were beyond saving.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201054_zpsyuisg3xf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201054_zpsyuisg3xf.jpg.html)
Calipers built up on the bench with new pads, pins and shims.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201053_zpsx68cajjs.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201053_zpsx68cajjs.jpg.html)
Attached to the car
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201055_zpsfvlcr7p0.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201055_zpsfvlcr7p0.jpg.html)
New dipstick (there wasn't one with the engine in bits). It almost matches...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201056_zps7hgdvces.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201056_zps7hgdvces.jpg.html)
Brand spanking new alternator. Far cheaper than it ought to have been - gotta love Mini Shows...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201057_zpsm75bdptq.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201057_zpsm75bdptq.jpg.html)
And the Rocker Cover that's too tall for the bonnet. Probably a combination of Mk1 bonnet, new engine mounts and, well, new everything.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201058_zpsa0zefjwa.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201058_zpsa0zefjwa.jpg.html)
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Good progress. Could you not trim the bonnet a touch or is it no where near able to fit under there?
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There's very little to trim. It's VERY tight under there, and with the 1275 being 3/8" taller than the 998, it doesn't help. A trial fit of the carb also looks like it won't clear...
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Its always them nightmare little oversights mate
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Those little details keep getting in the way...
The rocker cover looks awesome, a shame it doesn't fit in the space. Perhaps an original cover stripped and polished? (Not sure about chrome plated - could well be over the top - but I have seen them about).
Keep up the good work. Can't wait to see it on wheels.
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Thanks Bandit! Those little things certainly do get in the way... Ironically the engine came with a chromed rocker cover (original style) and I sold it... I think once the engine has settled on its mounts a bit more there *may* be a few more mm of room :laugh:
Tearing myself away from most things engine-related, I thought I ought to take a look at the wiper motor. This was languishing on the spares shelf and had been since I stripped the car. No More! Once I got it on to the bench I realised that it was filthy and in need a of a clean and minor refurb. As far as wiper motors go, it probably hasn't actually done that much work so a freshen up would most likely do. I stripped it down into its component parts, noting where everything went and started the deep clean. Typically the park switch broke but new ones are available and are not desperately expensive so I'll get a new one. The old one was disgusting though, so I probably did myself a favour.
I gave the wiper rack tubes a degrease, de-rust and spray in primer followed by satin black. I then did the same to the 3 parts that make up the wiper motor body. Interestingly the motor was dated 1982, which must mean that the original on the car was probably replaced at some point, this being a 1981 car. I shall hopefully put it all back together with no issues...
Wiper Motor in its component parts, midway through being cleaned.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201059_zpsypmkbn8b.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201059_zpsypmkbn8b.jpg.html)
Rack tubes mid-colour change
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201060_zps2dy2typt.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201060_zps2dy2typt.jpg.html)
Body parts in primer...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201061_zpsjlgkmwwk.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201061_zpsjlgkmwwk.jpg.html)
...and in satin black.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201064_zps0jrixier.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201064_zps0jrixier.jpg.html)
Of course, I did the main body too.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201063_zpsgvhug7ux.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201063_zpsgvhug7ux.jpg.html)
Filthy switch with broken locating pin. It might work again, but I'll replace it.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201062_zps2akuh5ov.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201062_zps2akuh5ov.jpg.html)
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Just a quick update today.
As I am likely to fit the tank fairly soon, I realised it needed the neck sealing ring (which I didn't have). Not to be deterred I found and decent piece of dense foam in the Manroom and cut it up until I had something approaching what is sold normally. it's a bit untidy but nobody's going to see it anyway...
I was fiddling around with the wiper rack tubes and the new wheelboxes on the bench and thought to myself "I may as well get these out of the way". So, armed with a 5/16" socket and the parts, off I went down the front end of the car. After some initial confusion where nothing seemed to line up correctly (I'd inadvertently put the wheelboxes upside down), the job was pretty straightforward; although having 3 hands would have made it easier. I have rubbed down the chrome plinths I have and sprayed them satin black - these will go on later.
Finally, as I was fiddling around in that area, I took a look at the washer tubing. I have always hated the way this worked on this car. It was loosely fed up the side of the washer bottle and through the bulkhead using the same hole as the wiper rack. It looked dreadful. So out came the drill and the vicious little nibbly thing (cone cutter). My first plan was to use a grommet and feed the washer tube through the bulkhead using a small hole cut by the bottom of the washer bottle. However, the fibreglass is pretty thick here so I had a rethink. It turns out that fuel hose is the exact size for washer pipe to run through, so I cut a 6mm piece and popped it into the hole I'd drilled. Looks SO much neater. Needs a tiny bit of colour matching (you can just make out a tiny ring of white...) but that won't take much to sort.
Homemade tank neck sealing ring. 5 minutes work with some foam and pair of scissors. I think I used a pint glass and a tin of polish as templates to draw round. I deserve a Blue Peter badge!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201065_zpsumw10an9.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201065_zpsumw10an9.jpg.html)
Small but satisfying modification to the route the washer tubing takes through the bulkhead. Much neater.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201066_zpsyyecimse.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201066_zpsyyecimse.jpg.html)
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More shenanigans have gone on in the past few days: I finally managed to get hold of the correct fan sender switch for the radiator - a proper "New Old Stock" piece so spend 12 seconds fitting that, then decided to drag the alloy wheels out to give them a once over. Of course they were filthy, covered in dust, dirt, overspray and spiders' webs. I also got the pressure washer out so gave them all a good blast. Now, the initial plan was to get them blasted, but as funds are tight I am not sure that they need it as they look like they're in quite good condition bar the overspray. A few hours with some wet & dry and they might be good for a fresh coat of paint. What do people think?
I then got back to the wiper motor. My new park switch had arrived so I could get back to putting everything back together. On went the new switch, followed by the motor itself, and I then sorted the wheel and greased up the rack and the innards. All is ready to go into the car now. One thing I could never stand was the way Minis had a piece of foam where the wiper motor sat, happily taking on water so it could start rusting through the bulkhead. Although that's not an issue here, wet foam looks rubbish once it's got wet, so I will be using some rubber drawer liner which I have kicking about. Fold it over and there's plenty of cushioning - a nice pad for the motor to sit on. I should be able to install it once I find the strap. I have made a modification to this as well, but that will have to wait until next time...
New fan switch installed. Fits beautifully.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201067_zpskxh9t4qg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201067_zpskxh9t4qg.jpg.html)
Dirty wheels about to pressure washed
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201068_zpsufrvxjor.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201068_zpsufrvxjor.jpg.html)
And drying off in the sun. They don't look too bad.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201069_zps0uznsztb.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201069_zps0uznsztb.jpg.html)
Old switch, new switch. No prizes for guessing which one I used.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201070_zpsmavuaheh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201070_zpsmavuaheh.jpg.html)
Motor and cam wheel installed
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201071_zpso93zqluo.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201071_zpso93zqluo.jpg.html)
All greased up
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201072_zpskvnotkez.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201072_zpskvnotkez.jpg.html)
New pad for the motor to rest on
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201073_zpsmvjayjkz.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201073_zpsmvjayjkz.jpg.html)
And the finished product. I just need to find the strap now so I can fit it...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201074_zpsgcuzmajh.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201074_zpsgcuzmajh.jpg.html)
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You only have time to loose with the wheels. If they don't come up with wet & dry after an hour or so you can still get them blasted. Although I think they will need to come up pretty good to match the standard of the rest of the car...
Are you going to leave them silver or have you thought of white? White would contrast well with the orange IMO.
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Nope - they'll be going black :cool:
I couldn't find the wiper motor strap I had so dug out the old one (For some reason I had two) and then proceeded to modify it in a similar way to the one I've lost. There's a problem that the Mini wiper motor lends to the Midas - Cracks. This is because when I got it, my wiper motor strap was held on by two rather large screws, which had caused the fibreglass to crack around where they'd bitten in. I wanted to avoid this, so decided to go down the good old-fashioned spreader plate method. Using 5/16" bolts, a strip of 3mm steel raided from an old Ultimate Engine Steady, 2 nuts and a welder, I made a decent spreader plate then proceeded to go about fitting it.
First I modified the strap by drilling out the screw holes to accept 5/16" bolts, then measured up where it needed to be on the bulkhead. Out came the cordless drill and 2 holes appeared. The plate lined up beautifully (I think I am getting good at this measuring lark). But I wasn't quite finished. I didn't want it to move if I ever needed to take the wiper motor off, so whilst held in place by the bolts, I spent a few minutes fibreglassing it in place (and enjoying the fumes). Typically though as I was moving stuff to start the fibreglassing, I broke one of the washer jets. I know they're only a couple of quid but "Grrrrr!" :angry: New ones are on order...
Although I didn't take any pictures, I have also remade my bracket to hold the gear selector in place as the curvature was all wrong on the first attempt. It's currently being painted. More to follow.
Wiper motor with strap, midway through drilling. You can just about see the edge of the rubber pad I'm using.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201075_zpsyhcwirsd.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201075_zpsyhcwirsd.jpg.html)
Spreader plate ready to go in.
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201076_zpsgcrhngkg.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201076_zpsgcrhngkg.jpg.html)
Bolted in place
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201077_zpsdi4mikiy.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201077_zpsdi4mikiy.jpg.html)
And time for little bit of CSM and resin!
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201078_zpsyeozcqvf.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201078_zpsyeozcqvf.jpg.html)
Oops - broken washer jet...
(http://i511.photobucket.com/albums/s353/MrBounce38/Midas/Midas%201079_zpsz8qkvjn4.jpg) (http://s511.photobucket.com/user/MrBounce38/media/Midas/Midas%201079_zpsz8qkvjn4.jpg.html)
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Right seeing as Photo-fcuk-it has turned itself into a favourite go-to site for ransomware, it is with a slightly heavy heart that I will no longer be updating on this site as once I have uploaded all my pictures elsewhere, I will not have time to edit 4 separate threads with close to 1100 photos on. I will be starting to upload the old pics back onto Imgur and editing in due course - please bear with me. If you wish to continue following this thread, please do it here:
http://retrorides.proboards.com/thread/191577/1981-midas-coupe-project-zippy?page=1
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Oh Crap! You certainly get your fair share of bad luck. I will follow you over to the new forum.
The upside for me is no more trawling through posts about Mk7 build weeks, where their missing foglights are and posts upon posts about the best detailing products to use on a new Mk7.5, because seeing your progress was the main reason I visit this forum now it has moved on from Mk4s and Mk5s.
I feel for you.
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Same here mate, photobucket have destroyed over 10 years worth of build threads for me too
I'll keep following you over on retro rides though as I'm a member over there
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Missing the updates on this car... I did enjoy following the build story. Any chance of a cheeky update?