2nd Gen R56 Cooper S Most liked posts in thread: 2" Cooper S Receiver Hitch

I got everything all done but didn't get around to posting final pictures until now. All I can say is I am more than pleased with my results. Everything turned out a lot better than I expected it to.





I whipped up a custom 304 SS thumb screw at work to hold the plug in instead of using a pin, it works out quite nicely.

 

Well I finally got around to getting my 2" receiver. I wanted a truly completely hidden hitch and the only 2" option I found was the MiniFini hitch but didn't like how it stuck out. I also contacted a few hitch manufacturers directly and they just suggested using a 1.25-2.0 adapter which I can't stand the look of sticking so far out. Eventually I decided to go with a custom builder (my dad and myself) to build a receiver. Once it was all welded together it was truly a bolt-on receiver, not even a cut in the foam!

Loosely going off the idea of the MiniDoMore hitch I went the route of integrating the rear bumper as the main structure of the receiver. Not wanting to have to take the rear end apart 800 times to design/cut/weld/paint/fit/cut again I found a rear bumper at a junkyard for $75! Can't go wrong with that.

Here's the receiver all mocked together before welding.


There's been many threads of hitch installs so I'll skip the removal process. As everyone else has noted, those two nearly hidden body clips PITA! Anyways, here's everything removed.


Out with the old


In with the new


All bolted right up

 

Another angle from underneath


Now the fun (nerve-racking) part. Cutting the rear valence. I wanted to be able to save the part I cut out and make that into a plug to make it really hidden. Having run out of good ideas on how to cut it, a spark hit me! Going to one of my hobbies of building and flying RC airplanes, I decided to use the Great Planes Slot Machine. Originally designed to cut slots for hinges in the control surfaces of airplanes, it doubles as a perfect rear valence cutter :devil: The tool works with 2 reciprocating saw blades that oppose each other so the cutting forces cancel each other.


Close up of the blades


That's as far as I got last night. Now on to put some finishing touches on, put all the trim and panels back on (after a quick stop a the auto part store for body clips :mad2: ) and test it out. More pictures to come when completed!

 

SUGGESTIONS WELCOME! It's bothered me since day one when I bought it. The left one slips off but the right one is bent and I can't get it come off/move.