Guy, Thom, Rhyso - thanks muchly! It's good to know people appreciate what I am doing!
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
Nearside bracket viewed from under the wheelarch, with stubborn nut and broken captive bolt.
And out. A couple of minor grazes from the Dremel. Time for de-rusting.
Subframe front brackets & spreader plates. These will be repainted. Note they're different...
Column out - seems in good nick - I will re-do the bushes though!
Rack not so good...
... here's why #1...
... and here's why #2
Mirror blank off. It's ugly under there!!
Odd rubber things from the back of the car
New old stock track rod ends. Yay!
Throttle pedal. Decisions, decisions...
Modified Maniflow backbox - I may well use this!
