Another Rally MINI Build

Discussion in 'Car Builds, Projects, Idea's Experiments' started by alexinvancouver, Aug 21, 2016.

  1. #1 alexinvancouver, Aug 21, 2016
    Last edited by a moderator: Mar 14, 2018
    inspired by Chris's thread about his rally Mini build i decided to bite a bullet and build a Mini S stage rally car.
    the goal was to build 2WD Production class car and to be compatible by the rules if it's forced induction it had to be 1.6L
    so Mini was a second choice after Fiesta ST but I have yet to see one being auctioned by insurance company where i buy cars.
    a bit of history: I've been rallying like all my life since 78 (or 79? lol) and had built a few stage rally cars.
    from 91 till 2011 i had a brake in rallying for like what? 20 years.
    In Canada since 2012 I was rallying 2000 Impreza n/a and had to compete against all turbo charged AWD cars
    because in Canada we don't have a separate class for n/a AWD cars.
    anyway i sold my beloved 2.5RS to some nice kid from Oregon.
    it was a nice car and a good build. all was done by myself

    IMG_5509.jpg

    so a few months ago 05 Mini JCW popped up on Insurance company's yard.
    it had some damage and i bought it somewhat cheap

    [​IMG]
    Mini Left.jpg
    brought it home and whatdoyaknow: next week MCS with the perfectly good front end showed up there!
    i had to buy that one too! for parts!
    fast forward: after selling all the unneeded parts from both cars covered the cost of the second one
    and even partially the first Mini.
     
  2. #2 alexinvancouver, Aug 21, 2016
    Last edited: Aug 21, 2016
    so the build began couple months ago but i was too busy with build, work and working around the house
    i wanted to finish it before Pacific Forest rally by the end of September but had so many set-backs
    now i don't see it done and slowed down a bit.
    here are some fun pictures:
    engine is out and body work is pretty much completed by now

    [​IMG]

    [​IMG]

    dry ice fun

    [​IMG]

    i can't believe the amount of wires this car has!
    i remember the times where i could make the fullcar wiring out of couple feet of wire and still had some leftovers lol

    [​IMG]

    making supercharger restrictor:
    it has to be 32 mm in diameter and placed within 50 mm off the blades
    took me 4 days to make out of solid aluminum block.
    inlet itself is barely over 32 mm at it's widest so i had to shave it first

    [​IMG]

    pic. of the finished product. it's now sealed by a scruteneer

    [​IMG]
     
  3. #3 alexinvancouver, Aug 21, 2016
    Last edited: Aug 27, 2016
    suspension-wise for now i have Impreza front struts (thanks Chris for the tip)
    with inserts revalved for high speed compression/rebound
    was going to install Bilstein HDs first but suspension travel was disapointing
    this is how HD compares with GC8 strut:

    [​IMG]

    for rears i have Bilstein offroad coilovers with enormous external reservoirs.
    ordered springs with helpers. picking up next week.
    hopefully they'll do the job
    still have to fabricate upper mounts and some brackets
    funny when they arrived i was almost in shock after seeing huge boxes
    and before opening them i was like: holy ****! did i order some wrong ones?!

    [​IMG]

    oh and of course i had to replace laterals with adjustable links
    from Dorman it is

    [​IMG]

    now before pulling the engine out i had to run leak down test and it turned out to be near perfect
    despite of relatively high mileage so i decided not to take it apart.
    just opened up bottom and replaced rod bearings.
    there was nothing wrong with the old ones and i'm sure they'd last couple rallies
    but still i installed brand new King Bearings

    [​IMG]

    control arm bushings replaced, clutch replaced, exhaust heatwrapped
    and engine is now almost ready to go in.
    just have to make a new pulley in place of a deleted a/c and fabricate a bracket for it
    also have to figure out what to do with front sway bar.
    either get rid of it completely or somehow find one w/smaller diameter.

    [​IMG]

    still waiting for the seats and some other useful stuff to arrive from UK
    without it i can't even start making rollcage.
    on a side note: Demon Tweaks screwed me up big time and that's one of the reasons why this build won't be finished in time for the next rally =o(
     
  4. MCS02

    MCS02 Moderator
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    Cool Build!:thumbsup:
     
  5. thanks!
    brake work will be done next week and then engine will go in =o)
     
  6. RallyMini370

    RallyMini370 New Member

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    woooooooooooooooooo hoooooooooooooooooooo Alex, thanks for finding the time to post about the build. MA home of 3 rally Mini's!
     
  7. 00Mini

    00Mini Well-Known Member

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    Very nice !! Looking forward to the next installment.
     
  8. Dave.0

    Dave.0 Helix & RMW Powered
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  9. #9 alexinvancouver, Aug 22, 2016
    Last edited: Aug 27, 2016
    No, Thank You Chris! =o)

    i know about that one
    BUT!
    here's the problem with it: that one sits very low.
    look at it and You'll understand
    [​IMG]
    dangerously close to bumpy runty rough road with big rocks on it =o)
    so while it's good driving on tarmac on stages any good hit will just shutter it in pieces ending chances to finish =o(
    so
    first i bought a pulley ($28 for that pulley without a bracket) and fab'd a bracket to place it higher
    but a few days later while working on 2010 Mazdaspeed noticed
    that drive belt has the same profile but idler pulley is much smaller in diameter.
    so again i bought Mazda idler (another $28 lol) and now making a new stud for it
    to be welded onto the bracket i already made. once installed i'll post a pic of it.
     
  10. RallyMini370

    RallyMini370 New Member

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    Yes I thought the same for the A/C delete so I found a shorter belt that works well but looking at the MCS you can't do that. Looking forward to your solution. Also nice to have a fellow creative thinker lol
     
  11. haven't done much yesterday. just removed rear trailing arm
    and spent an hour trying to figure out how to mount Bilstein on it.
    today i got these two delivered to my door all the way from Poland

    [​IMG]

    because i had some doubts the one i had already installed would pass the tech even if i slapped FIA label on it :mad:

    [​IMG]
     
  12. RallyMini370

    RallyMini370 New Member

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    For the rear struts you will need a washer to space out the bottom mount. Also the bush will need boring out from 13mm to 14mm. The top mount would either a uni ball top mount from Reiger or fusion of Subaru/mini. Another issue I had was the bottom bolts worked loose so I made a bracket to stop that. Carry on sir.
     
  13. RallyMini370

    RallyMini370 New Member

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    Oh you might need to grind a little off the trailing arm
     
  14. #14 alexinvancouver, Aug 27, 2016
    Last edited: Aug 27, 2016
    welded in Subaru tops. Mini metal was only 1.5 mm thick while subie plate is 2.5 mm!

    [​IMG]

    as for rear the main concern is a remote canister hose.
    keep in mind this shock has upper and lower kinda pillowball mounts
    it's designed and ideally has to be mounted like this:

    [​IMG]

    but can't be unless bottom mounts are totally re-designed because lower spring seat
    is pushing against the arm even at this angle and hose will interfere with top mount.

    [​IMG]

    so i tried a few placements including hose going back and it's kinda weird.
    plus attaching a heavy canister to upper lateral doesn't make much sense

    [​IMG]

    so i guess this is the only way even though i don't like it much
    because hose will be exposed to all the nasty stuff
    even when protected by a bracket and under-body protection which i still have to make

    [​IMG]
     
  15. RallyMini370

    RallyMini370 New Member

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    The front top mount looks fabulous. Yeah the rear strut is going to tricky. My my spring money is higher so the bolt works
     
  16. #16 alexinvancouver, Aug 27, 2016
    Last edited: Aug 27, 2016
    thanks!
    by the end of today i think i have it all figured out.
    started making it fit with the way they designed to be used
    less unsupported mass and no risk of damaging hose.
    upper mount is almost done, just have to weld it all together.
    in trailing arm openings will be cut to accommodate lower spring seat and then i will re-in-force it.
    pheeeew!
    ps. the springs i bought rated 275 and struts valving is 255/100.
    also i got helpers with dividers but i think those are useless with this valving, rate is just 40lb.
    should've just gotten longer springs instead of blowing money on useless stuff =o(
     
  17. 406geek

    406geek New Member

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    So great to see even more rally Minis in North America. Keep up the awesome work.
     
  18. #18 alexinvancouver, Aug 29, 2016
    Last edited: Aug 29, 2016
    i promise i will :wink:
    a/c delete stud still not ready
    today i made upper shock mount by utilizing the stock one. tabs welded under certain angle.
    and mounting points will still be original according to the rules!
    test fitted shock. hose fits right in.
    also permanently installed and secured remote canister :biggrin5:

    [​IMG]

    [​IMG]
     
  19. RallyMini370

    RallyMini370 New Member

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    yeaaaaaaaaaaaaaaaaaaaaaaaaaah go Alex go!
     
  20. Chris You were right.
    time i spent building this car i could've built two subies.
    ...and i'm not even half way there =o(
    i think anyone building stage rally Mini should be awarded a medal some sort upon finishing lol
    ...
    gosh i admire my welding skill lol

    [​IMG]
     

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