Another Rally MINI Build

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

  1. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    Yeah my legacy was a easy task compared to the Mini. Boy do we like a challenge. Lol. At least we are loved by the Mini world. Haha
     
  2. #22 alexinvancouver, Sep 7, 2016
    Last edited: Sep 9, 2016
    stud was done yesterday.
    can't believe it took him almost three weeks to make this simple thing!
    i came to his house to pick it up and the guy has this half built hot rod sitting in his garage.
    all hand made from ground up.
    and i mean every single thing including frame is hand made.
    but guess what? he started the build 23 years ago (yes, that's twenty three years!)
    ...and i thought my build is taking too long lol
    anyway test fitting picture.
    see how much higher it sits compared to original a/c.
    now i can take measurements and start looking for the right belt!

    [​IMG]
     
  3. RallyMini370

    RallyMini370 Well-Known Member

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    Nah 23 years is nothing for a scratch built car..LOL I was building a hot rod once but I sold to build a rally car. Nice one Alex, seeing as my belt lasts about 2 months before slipping I might look into this option. You said the wheel is from a Mazda?
     
  4. DneprDave

    DneprDave Well-Known Member
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    Oct 23, 2010
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    A buddy of mine builds about 1 1/2 scratch built hot rods a year and wins trophies at the hot rod shows with them! But that's all he does, he has a classic car restorations, hot rod building business. He has a three year backlog of customers waiting for him.
     
  5. #25 alexinvancouver, Sep 9, 2016
    Last edited: Oct 3, 2016
    pulley was for 2011 Mazdaspeed 3 made by DAYCO # 89015
    the grooved one
    probably regular Mazda has the same pulley but who knows
    belt hell knows what for lol made by ACDelco # 6K512 (88932689) 20x1315mm
    and could be slightly longer depending on bracket.
    i did some measurements and bought four belts to test fit.
    then returned three and one exchanged for a spare.
    now
    while making the bracket i didn't notice one mounting point sticks out a bit further
    and had to figure out why pulley wouldn't line up :confused:
    (btw bracket is re-enforced from the inside)
    had to bent one ear and re-drill it for lining up which was not a big deal
    primed and painted it yellow just for fun =o)
    and surely installed adjustable tensioner instead of the crappy and dead OEM one

    [​IMG]

    [​IMG]
     
  6. RallyMini370

    RallyMini370 Well-Known Member

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    looks good Alex
     
  7. #27 alexinvancouver, Sep 28, 2016
    Last edited: Oct 3, 2016
    Didn't make much progress because had to work on this baby
    ...gosh i wish i could keep it =o(

    [​IMG]

    Finished re-plumbing brake lines and took a while to install hydraulic handbrake and brake bias
    cut off a piece of metal and welded in a new one where handbrake cables go inside
    and un-drilled that base for hand-rest and airbag module.
    for some reason cylinder had two different treads.
    output had a tread same as seat belt bolts (WTF?) so i had to make a fitting out of one of them
    and input didn't have metric tread which is strange considering it came from UK (WTF again?)
    so had to buy one fitting.
    but now i can bleed rear brakes with handbrake lol

    [​IMG]

    also removed that big plastic shield in front of firewall and made a small compact heater intake box
    it'll ease the access to... whatever is down there in the engine bay lol

    [​IMG]
     
  8. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    There is a lot of WTF's in a Mini! I did the same with the heater surround. The duct from the heater I turned upside down.
     
  9. found a place for remote canisters.
    had to cut openings in rear floor supports and weld in half tubes
    cut battery box in half because battery will be smaller and relocated
    and i'll run a straight exhaust pipe. so that box will become a toolbox.
    besides it was hanging too low anyways
    ...got to speed up my build. the goal is to finish it by the end of November
    because we have a winter rally in December and i want to run it .

    [​IMG]
     
  10. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    ah your canisters are top mounted, the Reigers are bottom mounted which gave me some head scratching.
     
  11. MCS02

    MCS02 Moderator
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    Jul 31, 2009
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    This project is coming along nicely!
     
  12. #32 alexinvancouver, Oct 26, 2016
    Last edited: Oct 26, 2016
    was real sick for the past week with this flu
    the worst i've had in my entire life and still don't feel quite well
    nevertheless installed the engine today and will try to start it tomorrow if i figure out where to plug couple of lose connectors lol
    front suspension is done
    rear suspension is completed too.
    well ...maybe i should secure those brake lines?

    ...note to self: don't forget to pour some oil in the engine!

    [​IMG]

    [​IMG]
     
  13. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    Looking good Alex, sorry to hear you were sick and happy you're feeling a little better. Don't forget braided brake lines.
     
  14. no braided brake lines for me for now. will do in the spring before gravel rally.
    winter one coming in December takes place at the ski resort village high in the mountain (2 km high)
    and we'll see snow banks left and right ...but miraculously those banks have the ability to run across the road though =o)
    here: my clip from last year's rally with a first timer co-driver.
    he did a pretty good job for being a novice.
    enjoy the snow!

    https://www.youtube.com/watch?v=3yb0n9HeJUQ&feature=youtu.be
     
  15. #35 alexinvancouver, Oct 28, 2016
    Last edited: Oct 29, 2016
    the cheapest power bleeder in local automotive store is over $200
    so i had to make my own. feel free to copy lol
    a hole drilled in brake bottle cup: very tight for vinyl tube inserted.
    since there's some air in the bottle it pushes brake fluid down when bottle is squeezed by welding clamp
    also made a piston compressor. didn't have bolts long enough so had to weld two pairs together.
    pedal was still a bit spongy after few initial bleeds so i figured
    due to the bleeding nipple positioned in lower part of the cylinder some air could still be trapped inside.
    unbolted it and turned the end with the nipple up
    bled it again and now it works fine.

    [​IMG]
     
  16. 00Mini

    00Mini Well-Known Member

    Feb 24, 2013
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    ^^^^ Extremely interesting solution to a very perplexing problem.
     
  17. oh You'd be amazed what one can do when funds limited!
    now
    to keep things simple i got rid of electronic climate control
    and removed about a hundred sensors/motors/solenoids and some ducts
    and fitted Subaru heat control and subie resistor pack:
    made it only three speed and it blows to windshield and/or feet
    and manually adjusts hot/cold air.
    today's accomplishment:

    [​IMG]
     
  18. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    Ah for the love of Subaru parts on a Mini
     
  19. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    I found a power bleeder on Amazon for $50 just something similar to your creation! The problem with my clutch is it is not spongy, the pedal is rock solid with the slave cylinder compressed or with the clutch lever jammed part way the pedel locked up. My issue is the slave/MC won't push the arm far enough to release the clutch. A new MC is now delivered so next week we will see.
     
  20. #40 alexinvancouver, Oct 31, 2016
    Last edited: Oct 31, 2016
    it sucks when you have to wait!

    and Chris you're gonna love this one.
    i welded in subaru resonator hoping to muffle it down a bit
    but man she's still loud!
    when i have time i'll weld in some kinda muffler to it.

    [​IMG]
    and also welded additional heat shield to it
    and put some aluminum foil on fuel tank because i don't like this plastic thing too much.
    ...which makes me thinking: should i try to fit in subaru fuel tank?
    i'm sure i could lol

    [​IMG]

    she looks more like a car now

    [​IMG]

    and surely enough gave me the whole bunch of codes.
    some were expected
    and some were not and i'm not happy about that!
    i had two pages of codes. this screenshot after i got rid of some.

    [​IMG]
     

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