Project Zippy (Midas Mk1 Coupe) Engine In!

[MrBounce]

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.



More orange.



And yet more orange. Before I hit it with the garage door. Nuts.

[MrBounce]

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...



And clean again!!

[VW BUSH]

Wow an old oil filled jobby iirc

[Sam]

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. 

[Bandit127]

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...  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).

[MrBounce]

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! 

[Bandit127]

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?

[MrBounce]

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 

[MrBounce]

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...



...but not with what this once was.



So it's time to dig out the original (and horrible) dash cover.



In the process of adding tape-covered card which will peel off once fibreglass is dry.



First layer of fibreglass on. More modification will follow.

[MrBounce]

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.



New fibreglass where the horrible bit used to be. More will follow.



Refurbished Gearbox. 'Tis a thing of beauty. I have now removed it from the lounge.



Gaskets on with a smear of Blue Hylomar and half moon seal fitted.



No way was I forgetting this little fella!



Nicely where it should be.