Mini Ecoboost Project

Discussion in 'Classic Mini' started by Minidave, Jun 26, 2016.

  1. Minidave

    Minidave Well-Known Member
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    Dec 22, 2009
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    I started cutting in the new openings for the wheel wells.
    IMG20250306155918.jpg

    Since the right side was mostly rust and holes, I got new inner wheel wells, and I'm also moving it upward on the Q panel when I weld it back in. Although I'm not sure how much good they'll do since probably half of the tire is outside the fender (but under the Sport Pak arch)

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    Above pic is what's left of the right side inner wheel well.....bracket is for the rear mounted windshield washer bottle. I may take that off and remount it back in the front trunk area now.

    I don't know if I'll be using all of the floor panels, but there should be enough to fix the sills and the front edge where it's attached at the bulkhead floor at least.

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    My next and ongoing challenge is to start getting some of this rot repaired.

    My seatbelts came in too, and since I've removed the companion bins where they used to attach I bolted in a door bar to see where I can install them. I can either weld a bracket onto the door bar or build a bracket off the body, not sure which way I'll go just yet. Some of it may be determined by which set of seats I wind up using - right now I have three sets to choose from!
     
  2. Minidave

    Minidave Well-Known Member
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    Today was copy Binky day!

    I made a tool just like they used on Project Binky to bend up the lip under the arches, and it worked! I didn't do quite as good a job of cutting out the q-panel as they did, you learn as you go, right? The other side should go better.

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    So once the hole was cut, I used the tool to start bending the lip up, a little at a time, till I got it the full 90*. I had to do a little trimming of some other brackets and in fact I still need to ease one of them about another 1/4" but the inner wheel well fit and lined up nicely with the new lip. Once I'm happy with the fitment of everything I'll weld 'er in place.

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    Then I'll do the same to the other side and bolt the wheels back on and see how the clearance looks. It should be quite a bit better as I removed about 1 1/2" of metal. Once both sides are welded in place I think the next thing is to replace the rear panel.

    With that in place the boot floor lip (only about 2" of that will go back in) and lower valance can go in. That should stiffen things up all across the rear of the car. Then I'll weld in all the filler panels and build the rear braces for the subframe.

    From there I'll work forward.....on the door step, floors and sills.

    With those done I'll see about bolting in the rest of the cage. Once it's all welded and solid I'll put the motor in and start looking at all the other "to-do's'"
     
  3. 00Mini

    00Mini Well-Known Member

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    It’s always nice to see your vision start to take shape.
     
  4. Minidave

    Minidave Well-Known Member
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    Today I wanted to assess my work before I did the same to the left side, so I took the springs off the shocks so I could move the trailing arms the full length of the shock travel. I put the tire back on and ran the suspension up as far as the shock would let it go. This pic shows the clearance. The holes are for the attachment points of the Sport Pak arches, so it looks like they will clear ok.

    IMG20250310160847.jpg

    The I went to the left, unmodified side. Second and third pics show the wheel won't go all the way up without hitting the lip, so I was justified in my thinking on cutting the lips up....there was still plenty of shock travel to take up.

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    Lastly, today I gave the poor green Mini a bath - it hasn't been out of the garage for over three months so it was well past due for a good cleaning.

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  5. Minidave

    Minidave Well-Known Member
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    I decided to replace the rear panel in it's entirety, based partly on a recommendation from Dan - who pretty much knows about these things! I had another way to go , and I had panels for either choice....

    First choice was to simply cut off the bottom, rusty bits and replace them with a panel made for that repair, in hindsite it might have been easier than drilling out all the spot welds and cleaning up that mess, but like I said....I think replacing the whole panel will give a better final result. I hope so at least.

    IMG20250312131357.jpg

    1st pic is of the three repair panels, next pic shows the whole a panel removed.....I need to clean up any left over seam sealer and I'll need to get the flap disc after the remaining bits so I have a smooth seam to weld to. I also need to clean the e-coat off the joining surfaces of the new panel, and spray a little weld tru primer, then I'll be ready to weld er up.

    IMG20250313160647.jpg

    I left a little at the top on the c pillars, I'll clamp the panel up in place then slice that for a clean joint.
     
  6. Minidave

    Minidave Well-Known Member
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    1st test fit of the new panel....still a little trimming and clean up to do before I drag out the welder. I had hoped to get it welded on today cause the weather's been perfect.....mid 70's and dry. Tomorrow it's supposed to rain!......I also need to make a thousand holes to plug weld thru!

    IMG20250313184123.jpg
     
  7. Minidave

    Minidave Well-Known Member
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    I've been going slow on this project, mostly because I don't really know what I'm doing! [​IMG]

    Also, I don't want to weld something up only to have to tear it apart again, so I'm trying to make sure I'm doing this in a logical order that will all come together in the end.

    So I marked where I need to drill holes to plug weld the rear panel on, basically everywhere there wasn't a spot weld from before.

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    Then I decided it would be a good idea to clamp up the valance panel to make sure everything was square and fit the rear panel and the rest of the body. Before I did that I decided to weld the boot floor edge on first, that stiffens up the valance panel and gives something solid to weld the back panel to.

    So I drilled a million little holes to plug weld the two together, bolted them up using the bumper attachment holes and filled in the holes with plug welds. So far so good, it still fits up nicely.

    IMG20250320091135.jpg

    Next I needed to weld in the closing panels, but first I had to modify them as they no longer can go where they did originally - I had to make room for the subframe to be able to go in and out. Once this stuff is all welded together on the car I'll build some bolt-in brackets for the lower part of the subframe to attach to these panels. One end is done and I'll get started on the other later today.

    IMG20250320091043.jpg

    This sheet metal is pretty thin so I have to be careful welding it together that I don't blow holes in it....so far I've been lucky. Once everything is welded up on the valance I'll clean up all the welds and give it a coat of weld thru primer before I attach it to the rear panel. I also need to cut out the left side wheel opening and remove the inner wheel well.

    Then the next thing will be to weld those inner wheel wells in and tie it all back to the rear panel.

    From there I'll move forward to repairing the floors and sills. I've got a really long way to go on this project so I just need to get on with it!
     
  8. Minidave

    Minidave Well-Known Member
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    Surprise! Today I got a note from MiniTec that my axles are on their way to me......they even sent a tracking number.

    I have been working on the body, lots of cleanup, fitting, measuring, adjusting, more adjusting, thousands of holes drilled and swarf cleaned off but now it's all welded on again.

    The back panel is done except for the c panel joint which is just tacked for now. The inner wheel wells are fitted and welded in too.

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    I've got the valance panel all ready to weld on but I'm not sure I can get the subframe in and out with it in place. I'm going to bolt it back on now that the back panel is solid and see what happens. I do still need to add a bracket for the inner fender brace between the wheel well and the parcel shelf panel. That will be pretty easy to weld in once I make them. Oh, and fill the fuel filler hole.....

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    If the subframe will clear the rear valance then I can go ahead and weld it in place then build the brackets for the lower subframe mounts. Then I'll need to grind all the nibs off and give those spots a little primer.

    Next project after all this - floors and sills. before I can tackle those I need to clean all the sound deadening off the floors. I have a tool for that.....
     
  9. Minidave

    Minidave Well-Known Member
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    Today I'm grinding all the nubs off from my welds, it takes a while as I want to be careful not to damage the adjoining panel or grind thru the lip I just welded.

    Like my buddy Dan the bodyman says, 40 grit rolocs work pretty fast on them, but I just ran out so I need to find some more. I wonder if HF carries them? (Edit: Yes, they do - $4.50 for 3 in 36, 60 80 or 100 grit.)

    I also got my axles today....another piece of the puzzle

    IMG20250403144312.jpg
     
  10. Minidave

    Minidave Well-Known Member
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    Still don't have the parts for my air punch,, tho they show them shipped out via USPS on March 27th......

    Today I cut a chunk out of the old back panel to fill in the hole for the fuel filler. The panel is curved in two directions so there was no way I thought I could make a piece that would fit correctly.....my buddy Dan suggested cutting it out of the other side on the old panel and it fit beautifully!

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  11. 00Mini

    00Mini Well-Known Member

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    It’s really starting to take shape.
     
  12. Minidave

    Minidave Well-Known Member
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    So far yet to go!

    I also made some short brackets to tie the inner wheel wells to a vertical brace to further strengthen the side of the car.....I'll have pics of those when I weld them all in.

    I'm not completely happy with how the valance fits, I may have to do some mods to it. Since I cut out some of the wheel openings, the valance comes too far forward and intrudes in the wheel opening. I don't think it's enough to rub on a tire or anything, but it won't line up so I need to address that.

    That's the one neat thing about doing all this in metal, if it doesn't fit, cut it out and weld it up again!
     
  13. Minidave

    Minidave Well-Known Member
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    Work plods along, today I built the corner lower brackets for the subframe. I bought some flanged nuts to weld into the sheet metal so I can unbolt them when I want to remove the subframe. Next I'll weld the rear valance panel into place, then I can bolt these in and try the rest of the cage for fit.

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    I also acquired a sport pak arch from Dan to try, it fits perfectly but the inner edge return will rub on the tires unless I remove it, which might make the arch flimsy. I need to bolt a tire back on, remove the temp brace and reinstall the shock so I can see how far up into the arch the tire goes, and how far out it sticks. Ima give the arches some more thought before I do anything. Plenty of other work yet to do anyway......

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  14. Minidave

    Minidave Well-Known Member
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    So, after making the rear brackets and marking where the holes should go on the rear valance, I dropped it out and welded in some flange nuts. I made a little bracket so that I could set the height just below the surface of the valance panel and tacked them in place, then went around and tacked the whole nut in place. After that I ground off the nibs so I'd have a flush surface for the bracket to mate up to.

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    That done I bolted everything back into the car and to my complete surprise it all fit and bolted up!

    IMG20250430183125.jpg

    The back end of the subframe was only bolted to the parcel shelf, I needed to get these brackets in so I could unbolt it from the parcel shelf and add in the top parts of the subframe so I can see how it all is going to fit.

    Next up I'll pull the valance back off and make sure I've cleaned up all the weld nibs and get it ready to finally weld into the car.

    I also went over to Northern Tool and bought a couple of trailer fenders, with the idea that I may use those to form an inner fender from the q panel out to the sport pack flares, that should give plenty of room for tires - but I'll need to do some careful measuring first. If it looks like it will work I'll split it down the middle and have one for each side.

    The fronts will be stock 13"X6" wheels so std sport pak arches will work there, in the rear I'm looking at either 13X7 or maybe even 13X8 wheels.
     
  15. 00Mini

    00Mini Well-Known Member

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    This is a classic Minidave problem solving build project. :Thumbsup::Thumbsup:
     
  16. Minidave

    Minidave Well-Known Member
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    #196 Minidave, May 1, 2025
    Last edited: May 1, 2025
    So, looking at the Sport Pak arches, I went ahead and bolted on one wheel, and took out the brackets and installed the rear shocks, so I could measure the wheel travel compared to the arch opening. I know that it clears the opening in the Q panel but as expected it hits the return on the inside of the arch.

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    It also looks like I need to move the wheel back about 1/2" to center in the opening.

    Then I put my trailer fender in to see how it might work as an inner fender - the curve is exactly right although it's way too short - I would have to buy two and weld them end to end to completely fill the opening.

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    With the wheel in the normal position - about 1/2 of total wheel travel - it clearly hits the arch, but it does fit comfortably withing the outer limits - since I'm currently using 3/4" spacers it looks like I could at least run 7" wide wheels in the back, but 8's probably won't work with Sport Paks.

    I do have a set of Fortech knock off arches and they are super wide, so I know those will work no matter what wheels, spacing, offset or spacers I run but they are a lot of work to make look good. Still, maybe those on the rear and Sport Paks on the front? dunno.....
     
  17. Minidave

    Minidave Well-Known Member
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    Today I went ahead and welded on the valance panel, then trimmed off the excess. I also put a few tacks in where the panel meets the inner fenders. I'll need to go ahead and finish welding those areas, but I'm kinda thinking of adding a small bracket between the valance and inner fender, rather than just tacking the two panels together.

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    I think the next thing to fix will be the quarter panel, then the floors, then the sills. I'm not going to mess with the arches right now....I kinda need to decide what wheels I'm going to run, that will help determine which arch I go with. I could also use some of the Group5 arches....maybe.
     
  18. Minidave

    Minidave Well-Known Member
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    Next project - try this bad boy out!

    220V Miller spot welder.

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    Several issues.....

    1st, it's heavy as hell, 30 lbs is my guess. Trying to hold it still and clamp down in the right spot, time the weld etc? Fraught with peril! Need to dress the tips before I try it on anything too.

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    2nd, I'll need to wire up the appropriate plug, I do have a circuit available and a long extension cord.

    Lastly, learn how to use it to get good welds.....I guess I have enough scrap metal around to practice on before I attack the Mini body. Probably should have used it on that back panel for both the side seams and the flange at the bottom, but I know how to weld with the mig, so I thought in the interest of getting it done I should just use what I know.

    We'll see......
     
  19. Minidave

    Minidave Well-Known Member
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    Had to go buy an end for the extension cable, but Home Depot had one. So I gave it a try.....

    After welding these two together I could not drive them apart without tearing the metal, so it seems to work. I only gave it about 1 second of power too. I tried it a couple times for maybe 1 1/2 second but it made a lot of sparks like you see in the movies.....using 1 sec it didn't.

    I'm not sure where I can use it at this point, maybe at the top edge of the side of the floor panels where they meet the door step....wish I had tried it earlier, it would have worked great on that back panel!

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  20. Minidave

    Minidave Well-Known Member
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    Been working/thinking/planning on the q panel work, first I had to cut another 2" of metal out above where the patch will go as it's too rusty to weld to. Then I'm trying to figure out how/where to cut to lay in the new piece, plus I think I'm going to have to remove the A panel as the door step fits behind it - maybe I can just cut the weld at the bottom and slip it in behind the A panel.....these things are never straightforward!

    Next I cut a patch and formed the edge using my flange tool, this way the patch sits flush with the panel it adjoins and I don't have to butt weld the two together.

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    I was hoping to use the spot welder but I can't get the tongs inside this area square to the metal.....so I'll have to do as I have on the other panels and plug weld it. To that end I punched a bunch of holes in the outer panel and will weld thru to the patch.

    Before I weld anything I need to make sure I've done everything that's inside of this area as I won't be able to reach it once things are welded up.
     

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