Yes gentlemen, we can rebuild her..
First things first. Make sure that the fridge is full.
We quickly marked the position of the bonnet and removed at as it's only to get in the way the next month or so.
Covering her up to minimize any accidental scratches
 |
 |
The first job was removing the rear wheel bearings and the fuel/brake lines (as everything is going back new)
My Dad used to be a brake specialist at Girlock many years ago.. Luckily he still has some very nice tools to making brake lines.
 |
 |
The new main line is back in and new hoses on the rear.
The subframe obviously needs to touched up again as it has a lot of overspray.
 |
 |
We quickly stripped down the bearings (as I have new ones to go in) and cleaned up the hubs. I painted them to make them look a little neater.
Dad measured up the drums so he knows what size (or oversize) shoes to get.
 |
 |
Dad was obviously bored today so he rebuilt the brakes, made up the rear brake lines (to be bent) and packed the new bearings..
Retirement must be good for him ;)
Got the backing plate on and the new brake lines. Also cleaned up (at least from the outside) the subframe by giving it a new coat of black.
 |
 |
Got some brand new KYB shocks on (very nice). Also time to sit in it and go vroom vroom vroom ;)
 |
 |
Rebuilt the pedal cluster (after packing with grease) and put the master cylinders back (thanks again to Matt for rebuilding them)
 |
 |
Ripped off the front suspension and got it ready to a bit of a clean up
This weeks job is rebuilding the swivel hubs, front brakes and getting ready to look at the fuel lines.
 |
 |
Got the front swivel hubs on with all new bearings etc.. Everything went on extremely easy which I'm grateful for.
|
 |
My Dad made up all the front break lines. He wanted to try something different for the master cylinders and came up with a very nice design.
My Brother bought over is engine crane (complete with new hydraulic ram which is air driven). He also organised some battery fittings and made up some leads.
We are looking to drop in the engine next week. Look it's Christmas, there are more mini decorations hanging from the xmas tree..
 |
 |
 |
Stripped the heater core out to make sure it was ok and to replace all the foam. I resprayed the casing
with some vinyl/plastic paint which I must admit came up very nice.
 |
 |
Repainted the engine bay so the black is not 12 different shades of gray.
The big day has finally arrived, time to put the engine back in. Anthony brought over his load leveler for the engine crane which made the job a LOT easier.
It was tight getting it in with the extractors on but it went in quiet smoothly. Its nice to see it all in place.
 |
 |
 |
 |
Anthony did a great job of doing the main power wiring to the start solenoid. Shorting it out caused the engine to crank (which was a joy to my ears)
which meant we had a good earth. All the brake lines and now in place and everything starting to look like it should.
 |
 |
Rebuilt the heater and put on some new hoses.
 |
 |
The bolt on the steady bar was a damn bugger to get on (mainly because the extractors where in the way). Had to loosen them to get it on.
Still to to wrap wire around the split pins (stops them sliding out)
Time to buy all the fluids and clean up some of the interior parts. The plastic paint does a lovely job of making things look new.
 |
 |
Put in the fuel lines and made up the custom rig for the twins (need to get more fasteners). Installed an electrical fuel pump in the rear subframe.
 |
 |
Started getting ready for the fuel tank to go back in. Had to drill a hole in the floor for the drainage plug to snuggle into.
(Though I'm waiting for some light gaskets to turn up first)
Got the wiper motor and assembly back in. The washer nozzles and started on the wiring harness (though will be covering most of it up) and the compliance plate
(after polishing it up). Was a hard day due to 44°C heat (probably hotter in the shed but I had both fans going).
 |
 |
Well after finding out that solid copper is not allowed for brake line (funny as we bought it from a brake shop) we replaced
it all which
some very shinny steel lines (which where a lot harder to bend and shape)
 |
 |
With the help of my brother (Anthony) got all the electrics and lamps in. Every things works and the motor even attempts to crank
when you turn the ignition. Thanks AJ.
 |
 |
Continued to work on the wiring and making it look neat.
 |
 |
Bolted on the rear bumper and started playing the exhaust. Also put on the distributor after aligning the points.
 |
 |
And lastly (for today anyway) got the brakes and clutch inquired up and ready to roll.
(Thanks to my dad for showing me how to bleed the system and adjust the brakes)
Finished up the rear wireing (including the number plate) and put in the fuel tank
 |
 |
The almost finished look from behind (still got the lamp plastics to go back on and the exhaust).
Out all of the bolts on the mini, the bolt holding the fuel tank in HAS to be the HARDEST bolt to tighten. Why didnt they pull it down from below instead of
pushing the band down.
Took a bit a thinking and some nice tools to get it tightened. (I've since bought a nice tiny universal)
 |
 |
Got the exhaust finished and on thanks to my brother who made a custom bracket for it and welded it on. (this we due to the fact that the original
owner cut out the rear subframe (pics elsewhere on the site) which we rebuilt and as such the new exhaust didn't fit the non-original mini layout. It does now ;)
Also put in a fuel filter before the pump as a secondary.
 |
 |
Got all the water hoses on, the front bumper and under riders. Its starting to look like something now.
Hopefully it will be ready to fire up in a days time.
After trying to fire her up, we found that the right hard carby jet tube was fractured which caused a bit of a stumbling block. Thankfully we
had a spare on the original which became a donor for the new one.
 |
 |
And after giving it the kiss of life... (and putting the oil pressure sensor in properly)
Been a busy few weeks doing non mini things but been purchasing bits for the next round. Roof Lining, Dash,
Straps, Jets, Locks, Handles, Clips. Its all there.
Build up the dash cluster panel which required a little bit or work (nothings easy right). Cleaned up all the dials and got
it fitted with a bit of trimming and adding a few spacers. Looks very nice. The pic doesn't do it much justice.
 |
 |
Finished doing all the wiring, ie getting the heater working, wiper motor etc..
Then put in the dash board which looks sweet.
 |
 |
Was having some breathing problems (well excess air) with the engine which was causing oil to come out of the dip stick and a bit of back
pressure. After talking to lots of people the best thing was to buy a side breather from a Mini Cooper S (at last I have some pedigree on my car).
Took about 2 hours to fit and wasn't the easiest things to do (had to remove the entire carburetor manifold
 |
 |
With a bit of silicon and a few bruised knuckles, it all went into place.
 |
 |
After putting everything back its hardly noticeable. Still got to get a pipe to run it to the SU filter so it can be back fed back into the engine.
Also spent a bit of time painting up the back of the grill (the front will be half black/silver) and putting all the glass into the bath
to get rid of the tint etc.. (this has now been done).
 |
 |
And lastly, congratulations to my Brother and his wife Michelle on the birth of their first born son
Brock John Leathley - 23rd January 2008
Order in some Smithz dials and a KAD gear stick (which is awesome). Not cheap but well worth it.
The left carby has been giving up a hell of a time so we stripped it all down (AGAIN) the replaced the needles, jets, lid (as the old one has a micro fisure in it).
After a long slog we replaced almost everything and now it works a dream.
 |
 |
Got the new gear stick in and the T-peice for the oil presure guage.
 |
 |
The new dials look brilliant and fit in with everything else.
 |
 |
Also tempraraly put in the back seat (which was upholstred by the previous owner) for a bit of fun. The car is booked in to go into the car trimmers
in 2 weeks so that will get all the carpets, door trims, roof lining, seats etc.. all done which will basically finish up the interior.
Getting close now..
In went in all the new door rubbers, chrome, locks, handles, strips etc. A lot of work and very fiddly getting everything back in the right order
(And belive me, there is a order). Adjusting the locks was much harder than I thought it would be.
 |
 |
Got the bonnet back on and washer bottle. Basically complete now.
And after quickly bolting in a seat (well bolting is loosly termed ;) took her for a quick spin up the road and around the local round about.
Was fun to drive after so long and she has a lovely engine note.
|
|