All over the place

 Since the last update I have been ... Yep all over the place on the mini. Well it felt like it.

I decided it was time to go visit the back up engine in another garage. It was filthy, so got down and dirty cleaning it up. Couldn't help my self and I had gone prepared with the drill and wire brush to clean up the ally bell housing, to get rid of the oxidisation.

With that little spruce up done, I moved on to fitting the new clutch and fly wheel. With the fly wheel fitted it was the first time I was able to do a compression test. Nice and even figures, so called it a day on the engine.

Work on prepping the front hubs continued. The second caliper has been stripped and painted, leaving me just the seals to change on the second one. The calipers split in half, bit of a shit I managed to loose 2 bolts that hold them together, sourced some and they are in the post! 

On the front hubs, where predictably taxing to remove the castle nut. But out came the big torch, a 1" drive socket set and a very long bar.

The ball joints where removed and just left me a truck load of thick old black grease to remove before I get round to replacing the ball joints and wheel bearings. I did split the wheel nut plate from the old brake disc, painted the brake disc shaft, I was good and masked it off. I might not have been bothered to go to the garage to get a Stanley blade, so the kitchen knife was a great substitute! Always pushing my luck, well I have been cleaning and painting the calipers in the dinning room so why not. When I find the torque setting the wheel nut disc can go on the new discs all ready for when the hubs are finished.

So the end to my weekend was yet another order with mini Spares... For another £100 of parts, which I am almost getting used to being a disappointingly small box when it turns up. But that should be all the parts to finish the front hub refurb complete and the last few bits to bolt on ancillaries to the engine. Which I hope just leaves the carb to sort out for the engine.

Tiny update

 As ever progress but not ground braking. Having to think hard, as much as other bits of life have not left much time for the mini I have been on it.

Door cards, I must have mentioned I had reglued the covering seem/edge back down to the reverse of the card. As the door cards are obviously stored lent up against the fish tank in the dinning room! I noticed recently as walked past them a nasty curve between the trim poppers, I expect they have a proper name, the bits that pop into the door skin and hold the card on. As that end was on the exposed end when open, I got back on to the idea of making the cards and re using the covering. It's still in good nick and I like them. After many measurements and second guessing a little due to the partially blown card, I had it all. At work I programmed and cut a prototype which ended up being pretty dam close, add a little BL tolerance with oversizing the holes and we should be good.

The keen eyed might notice the window handle hole is off. We shall just call that one of those moments. Checked it over and just have no idea what I was thinking when programming that, it's noticed and easily sorted.

Checking the prototype on both doors I gentle dug out and later on the lawn, I re noticed the scuffs on the top frame. Poss done when I brought them home in my car? I also noticed the paint going to the window rubber was patchy. A quick clean up, mask up, paint,clear coat and all is good again. Was quite glad it's done, as the temp will be staying low now and I don't want blooming in the paint. So made the most of that bright Sunday afternoon.

At last I got the other calliper off. Went to my friends and used his duga duga, or an impact gun if your posh. One stone gaurd is sandblasted and sprayed the other is in the que

The above is just sandblasted, but what a difference.

The last thing I did was pop round to my parents where the second (stop gap) engine is stored. I needed a fresh look at it. A couple of bolts missing and dirty, of course. But it has all the brackets there, water pump, fuel pump, silicon bypass hose and it's had fairly regular oil changes by the look of the clean rockers. It still turns over by hand, so all was looking good apart from the missing dizzy cap. I then fiddled with the clutch arm, nice and free.... I took the bell housing off and there is zero clutch, yay!

A full kit with fly wheel £260ish, bugar. I have already been looking at caliper seal kits, discs and pads on top of a few other small parts. It was starting to mount up, again, sigh. A few messages with a friend who is cutting back on his parts and I should be getting full clutch, discs bearings and ball joints for £140. Quite relieved and thankfull, I'm waiting to collect the parts ready to attack the next phase.

A ray of light. With my friends parts, that could see the engine together enough to drop it in the car, and with front brakes overhauled, bearings and ball joints. This is getting closer to the right hubs and wheel offset for the first time, as they are metro bubs at present and sit wider than they should.

There will still be all the ancillaries to sort out which some are already prepared and others need sorting. As this wasn't the planned engine it needs some different spec bolt on's. Glad I didn't sell the spares as I now need them! But the to do list after the engine and front hubs might fit on one page... If I write small ! 

A little more

 Bits and bobs was on the agenda.

As the boot lid was getting close to instillation I thought changing the boot lock was a good idea. Obviously that meant I had to clean and buff the handle till it was gleaming and set about stripping it to change the barrel. Having watched a YouTube video to make sure there wasn't any quirky bits that would catch me out... It's a mini, of course it's quirky! A sort of circlip holds most of it together and a sneaky tiny locking pin needed to be drifted out. Then just out in the key and use that to draw the lock out. Sounds easy, lol. The circlip and pin where easy but not having a key slowed me up. So it was brute force/wack a screwdriver in it and turn/pull. 

I might have installed the handle upside down (the key was upside down) the first time, I sucked it in and re fitted it having wresteled with "can be arsed, is it really going to matter" and the fixing bolts where a bit taxing. Would only bug me latter!

With that done I found the other boot strap fitted that and set about bolting on the boot lid, it linned up ok which was a surprise but all nipped up my word it was a bit tight to close. It's a new boot seal which do bed in so we will see if I need to add another gasket on the hinge to ease closing or it beds in. I already have a spare pair so no big drama.

Bulbs.... Owww!! So the mini is old, bulbs have improved, and become a pain. Orange indicator bulbs are just simple standard bulbs.... Nope new ones have off set pins and I need parallel pins. Eventually found the right bulb code and bought some, argh, that's the rear lights finished. Front side lights... Same problem with the pins! I had only just exchanged the indicator bulbs at Halfords that morning for petrol resistant lacquer to do the inside of the boot lid before it was fitted. Yep I have spare bulbs for the, more modern, daily car now! 

A few days ago it was time to stop putting off the fog light switch. Made in 1980 it was not required to have one but five years later they made it law and back dated it for cars made upto five years prior. This meant the wiring loom does not have the wiring to the switch but I had installed a new rear loom so I had wires... Just no where to put them. The brake test switch which is often not used or hidden behind the dash has been sized up to supply power and light to the switch. The theory is good, I really do want to get some power on the car and check the multiple tweaks I've done have all panned out ok. Watch this space.

While I was on that the discoloured switches bugged me. I quickly found that cleaning did next to nothing but a rub with my nails took the grey white discoloured coating off, not the quickest way but a nice result. Especially as I have been told by many the new switches are simply shocking and don't last so refreshed old ones is much better. Happy with that, re use and save a few pennies is always good.

Jumping back a bit, I knew the squirties would be coming up so I dug the screen wash bottle out. Yuk, dirty! Now would be the easiest time to clean. Had to use a few poky tools to get the inside corners and a Stanley blade to gently remove a odd burnt bit on the bottle. It looked almost exactly like my spare, I was pleased with the result. Still don't want to fit it till I sort out the new pipes for it but it's good to go and a easy install.

I have now moved on to the front suspension/hubs while I wait to fix my daily car and know I have the money to buy the latest round of parts holding up some of the current jobs.

One calliper and stone gaurd is off, that calliper is cleaned up. The other one is being stubborn and I may have smashed my finger quite well trying to remove it. That's why I'm doing this instead of getting dirty, badly brushed bone means not enough grip and I'm also sporting quite a few cuts. Keeping the hands clean tonight!

The stone gaurds are 2 parts held together with a Phillips bolt and crappy nut. Really? In a place that gets caked in water lots. Well done. Mole grips and undid them quickly so the boot would shear. It was a 10mm nut so the metric replacement I was going to fit won't be out of place. Do I really need to say, the stone shield I have off is already sat next to the sand blasting cabinet waiting to be cleaned up.

As these where donated to the cores and have been sat up for at least ten years, a full service kit was always going to be needed. Seeing the pad springs fall in half just confirmed that idea.

I have private work to do this weekend so not expecting to much progress for the rest of this week. But may get a chance to remove the front cones to replace and out the hi lows in as well. We will see.

Slowly does it

 As you may guess, it's been slow going. Been really busy with other projects and life, leaving little time for marmite. 

After a few subtle improvements to the tank bracket and its location. The tank is fixed in with fuel and vent pipes fitted, both boot straps are fitted, rubber seal cut to length and fitted, also the hinges are fitted to the car. 

Today I did get a spare bootlid to rob the latch, handle and all the bolts. Another stint of spit and polish/paint on those done

Technically we should be good to go and able to fit the boot lid once I have changed the boot lock barrel. That will pretty much be the back half of the car finished!

A while back the paint hanging tree (bird feeder) was in use while I colour coded the door hinges, getting the doors a bit closer to the assembly.

Other things getting closer. Removed the rear light lense to swop the inductor bulbs for the orange hasn't flaked off these bulbs. Saved the old ones by putting the in the front indicators as the have orange lenses 😉

Also bought some side light bulbs, a quick bulb stint soon and all the lenses can go on for the last time. By the way the front indicators/side light are fitted and the headlights. All wired up as well.

Finished the re furb on the windscreen wipers, with a bit of a fight there are installed and plugged in. 

I started to complete the screen washers but the pipes are past their best and the bottle needed a clean. It has come up nice though so worth it. Will add a picture in the next couple of days.

Slow but progress is being made and more close to done, just need to get over  unabtainable brackets to mount the switch panel then I can move to the front end.

Boot work

 To get a few parts fitted and safe I decided the tank was long overdue. It was held up a lot by other jobs being done before it could go in. But they are done and it is hard to describe how annoying the tank has been just laying around. Well massively and constantly just in the way. I have lost count of how many times I have painted it, because I wasn't happy or I'd just scratched it again.

On the latest stint of paint the tank again I was not happy with the metal tank strap. Yep it got ground back to metal and painted. It just looked bad against the nicely painted tank and the paint was out any way. 

All of this led to a desperate need for the bottom bracket for the strap around the tank to bolt to. I was told it could be bought and was expecting a little bit of welding it to the boot floor. Well I couldn't find it any where, so I made my own. Much smaller but much stronger. 45 mm x 5 mm thick angle cut, drilled and edges eased. Sounds easy, but I might have over heated the captive nut I welded onto it, but my neighbour had a m8 tap and corrected that. I also had to go visit Emma and double check her mini to work out the exact location for the bracket. There was just no reference point I.could find for it and having moved the neck, I really wanted to double check this.

To mount the bracket I decided on just drilling through the boot floor and fix it with just a nut and bolt with a nice penny washer. Until the hole lined up with the side quarter bottom valence, yep the enclosed quarter section. A day later I had the rivnut set and was back on track. So at present the tank is in the final position, with padding under it on the boot floor and the strap round it waiting for a longer bolt to do the final fixing. Even put a boot strap on as well.

I do try to save time occasionally, and the black paint was out doing the tank. The windscreen wiper is another item that always seemed to.be.in the way. A replacement wheel box had arrived and it was looking like that could be finished. The plastic motor cover I picked up wasn't looking so appealing any more so the partially black painted motor was sanded back and painted. The wheel box was removed and all parts got a good clean then grease before re assembly. The original wheel box took quite a bit of cleaning, getting the gunk out from behind the main cog was slow work and a lot of wd 40. But with a  careful poke to get the soaked cloth behind it was turning nicely.

I ran out of time and motivation tonight to install this last part but the motor has been.tested now, so a little patience and it will be finished soon.

Through the looking glass

 Yep, windows was top of the to do list. Started the rear window, which was fun. The rubber seal kind of went straight on, but of a faf. Was a fiddle to get it on and the C pillar trim needed trimming back from the window opening just a smidge. I had seen some one struggle because of the opening not being big enough because of this, so cut to the chase and sorted that before it was a problem. With a lot of lube the glass was teased in ok, then it was time to fit the beading. I had bought the special tool to do this and set at it. It really didn't want to seat right at the start, several attempts and I decided I would just have to go back to it and flick the rubber fully round it later. I did the first corner surprisingly easily, then upto the next and that went well. Then along the top edge of the window .... the bead would just not sit right. Forwards then backwards and then I realised the tool was just moving so slowly ....  I gave up/paused for the day. Tennis elbow was kicking in. I had been bracing mt self against the side of the garage whilst fitting the bead. Yes it was being that stubborn.

Under advice I added lube to the bead channel in the rubber the next day. So much better, still not a fast job as the bead needs to sit just right. Managed to trim the bead to just over length to allow for shrinkage and popped that in. I went back the the starting piece, hmmm that didn't quite go according to plan. It started ok flicking the rubber around the bead, then I slipped and run the screwdriver down the car! A lovely stripe of primer revealed, sigh... later for that job!

Have a look here for a few do and don'ts on fitting the glass. Video

The next stint was on a side window, went in nicely and then the I did a dry run for closing it. I know with new seals this can be a pain, just couldn't get the window closed and the catch to be sure of where to pierce the new C pillar lining for the catch fixing holes. So paused for advice and reference from the club.

With a nice ref picture from Emma (she has been a great help with knowledge and ref pictures) I tried again. Still not quite happy the seal was peeled back and I measured the fixing holes in the body work, put it back together and went for it. Which worked out nicely.

In between the pauses on that side window I tried to get the drivers one to the same stage. The bloody metal frame on the window had come away from the glass and made the outside diamond shaped compared to the opening. So that was cleaned up, glued and clamped.

Today that one went in and fairly quickly for a change, oh and I clipped the sunroof in some time between the side window stages.

Talking of which, in another moment when I was avoiding the side windows I fitted the front headlight bowls and lights, also managed to get one side light/indicator in as well. Sounds easy, I had to re wire the indicators due to only have 1" long wires before they where joined with another bit of wire. Hmmm that join by the way, was just the wires twisted together and that was mo way close to good enough. Managed to get the bulb fixing out and replaced the wires so they where new and long enough to reach the main loom. Really liked the prep when I was fitting them, nice clean wires and ages ago I had replaced the fixing bolts for marine grade stainless steel bolts :) there is a little fiddling still to do where the light wires join the main loom, but I have a clear plan and the work wont look out of place. Even managed to keep the same coloured wires again with identical connections. Will be wiring up so both side lights work but in a way they can be easily disconnected and worked on. You will see about the "both" when I test the lights (round nose lights but a clubman has separate side lights).

Tonight I sucked it in and repaired that scratch, sadly I think I have a better shine on the repair clear coat than the original one, so a bit of polishing to try and blend that some how. No picture as my phone was dead and charging.

Getting there as I'm not completely sure of what the next step is, a couple of small bits on the to do list but thats all at the moment.

Suppose it is either sort the dash switch panel out, fit the front screen or fit the door glass and hardware to get them on the car and out of the way. I colour coded the hinges a few weeks back so should be "just" add the fittings and buy new nuts and shims to fit them. Front suspension change after that !! That prob would put me on or very close to engine after that, eeek, that might be a glimmer of light at the end of the tunnel!!

Snagging

Again there was a few little bits that had appeared on the to do list.

While I was trying to work out how to solve the cotton real mounts for the gear selector linkage so the carpet could go down. With out paying more in postage than on the parts.  I went through the bundle of new parts that had turned up, which yes, I had forgotten to add some cotton real mounts. One of the parcels was seat belt bolt covers. I found a place for these standard covers and ordered 6 for less than I could buy 2 from a mini specialist. Subtle, but a nice touch for just a few £ and a very quick straight forward job 

 I decided to mount the accelerator pedal and steering column as I had put a new ignition barrel in, all posh now with a key and painted/cleaned up! Also really getting annoying with it being on the dinning table for over a week! All went well and I managed to line up the pinch bolt on the column to the steering rack, then I broke the weld where a patch was nibbled by a grinder from the previous owner of said bracket (from the dash, and it isn't made any more). Looks like that will be coming back off for a proper go at welding it back, it really isn't much but it should be done. I did add some carpet around the column base, as it had been cut quite generously. The off cut from the speaker cut out on the parcel shelf worked a treat.

For the last few days the garden has been covered in windows and a front grill. It's really looking like I have a problem, parts all round the house and all over the garden as well as in the garage and loft!

I wanted to double check the glass and start cleaning them up ready to re tint some of them, as the tint had turned up this week. But by then I was gearing up for a parts run, so window tinting was put on the back burner. 

Earlier this week I had checked the budget/funds, I knew that I should be getting the engine sent off for rebuild while I finish the rest of the car. With a fairly large and uncertain bill for that and knowing I still needed to buy the correct wheels, tires, coil, starter solenoid and almost definitely some other parts as well. The sums took me way over what was left in the kitty. The straight forward plan was finish off the interia, fit up the doors, refurb and swop over the front hubs/suspension and put the cover over it till the savings where better. Option B was suck it in, go for a smaller and cheaper engine. From day one, all I was interested in was the 1275 but that was looking like adding at least another year. Option B stands a chance of the mini being done this year though so I started looking around.

Having tracked down the family tool club engine hoist and arrange loan of a small van. I got my sheets and lifting strops, got some food and drink ready to get the latest round of parts .... a 998cc engine from a chap who races minis and some other bits as it was a job lot.

Yesterday was very hot. Was smug we set off early to Salisbury for those parts, but getting back after lunch and unloading the engine at my parents and then 2 sets of alloy wheels, a clubman bonnet and a pile of old bumpers at home. Yes I still have a set on the car which are only on it so it can be moved and another set (of 3!) In the garden. I just didn't have it in me to work on the mini with all that in the morning and the heat. Sitting under the sun umbrella washing a set of wheels and listing them I did manage. Finally a bit of money back into the pot and a local mini owner very happy with his bargain.

I will try again to tint the rear window today so it can be fitted .... off the shelf, out of the way and another job done. Well that's the plan ?

Last of the cabin carpet

Last night the clear coat on the switch panel bezel was done and carbon wrap also done on he switch panel.

Attacked the accelerator pedal mounts today. One if the captive bolts had been sheared off with just a little stub left there. Out came the die again to clean up the thread on the good bolt, dropped the pedal bracket over the 2 bolts and then .... drilled a extra hole so I can fit a special bolt to make sure it can.not twist. Then it was spotted I must have sprayed the pedal from the back leaving a patchy coating on the front. That was hung up and sprayed while I got on with contemplating the last bit of cabin carpet.  This bit goes on the bulk head but still under the dash. Did I say the last bit ? Or so I thought when I first went in the garage.
Whilst doing that I had a good stare at the cross rail on the floor pan (where the standard front seats mount and hinge from). Yes, it seemed a waste to not template the exposed bit of the cross member while I had all the materials out .... why stop there when there is nothing under the hand brake handle as well.
Several templates later I was set to cut up more carpet and glue that on. Worth it as it would have bugged me later on.

Talking of possible regret, the front carpet came out to keep it clean with this round of glueing. The cut right in the middle that would prob be hidden by the heater, had opened up again. The gaffa tape was a bit hopeful for holding it together , so while it was out plan B was executed. A hessian sack a nabbed was cut up, contact glue applied to both and slapped it over the cut. I really could not work out why the previous owner had done it.

Now feeling confident the carpet will lay nice and flat now, and kind of waiting for the parts to turn up for the next round.

Trim tweeks

Yesterday the sunroof opening trim turned up. Having checked quite a lot of sites and trawled through so many profiles, Phoenix trim came up trumps.
At first I thought it was a bit small, but at the first chance I git I was down the garage and fitting the trim. Oh yes, it was spot on and got the trim to length just right. Overly excited when I stood back. But that is almost the sunroof saga over, lost a lot of sleep over that so its really nice to be getting there.

In the latest bundle buy was a switch panel. It's solid and straight, but scratched, tarnished and slightly rusting. Nothing new there, getting used to it. With the ally thin frame really not looking all that good, it forced a little think about how to improve it.

Having re found the silver and Kevlar  handbrake lever cover and fitted it. I was leaning towards Kevlar on the flat switch panel and filling then colour coding the frame. A lot of sanding, priming, sanding and finishing in the car colour. We are getting there and should be finished tomorrow.
I forgot about the gear selector unit. I checked the mountings for it and finally double checked the odd opening for.it. yep its wrong, not by much but enough not to seal to the standard gear stick gaiter. Being such a small but I used a sheet or 1mm ally and cut a panel.

Starting to look luke a car

More short rounds have been taking place when I get the chance..
The rear door bin trim and arch carpet (after I made the carpet template) has been fitted, and looking quite good.

 The rear seat belts are finally completely fitted with the parcel shelf carpet and speakers fitted as well. The trim under the rear window has been fitted as well as the rear heated window ground, I had to make up that lead. But the old mpi  loom helped with that again.

With that all done I was able to finish routing the speaker wire to parcel shelf and just grab the rear seats, which I had given a good clean a few days before, and fitted them for the last time. It was well worth the effort of straightening the metal base and lip. It looked bad and gappy before. A fresh coat of black on that as well brought it all together nicely.
The led lights under the rear seats where fitted as well when I did the speaker wires. All nicely clipped out of harms way.
Really nice to have the car tidy and it should stay that way as well.
In the front, the top dash rail was cleaned and fitted. Attention moved over to the peddle box. All captive bolts and nuts had a tap or die run down them, after it had ... just one more coat of paint!! Proper shinny, thats what we like.

Even after I removed the steering column the peddle box was still being a bit of a pian . Pulling it tight with the bolts into the engine bay helped a lot to get the 2 bulk head bolts in.
Then after a quick look at the clevis pin holes in the peddle ends .... I clearly need to buy some the right size. A local shop had some but a test fit will decide if one or both need trimming to length. Before final fitment. That looks like a royal pain in the butt so looking forward to that!
The boot has been cleared out again and the petrol tank tested. Which just passes the speaker so all is good there and ready for the last few parts to be fitted in there.
The rear speaker wires where fitted to the stereo harness plug.
A bit of time was spent on the gear selector box, cleaning, painting and wiring.