Most liked posts in thread: Rally Mini Cooper

Finally! it was stalled for a while and with me being only there for 3 weeks out of 5 I have to make every hour count. Plus I'm stripping down the Suzuki at the same time.

 

hahaha thanks Steve, that link is where I got the idea from! Thanks M/A together we are going to make a good Rally Mini

 

I build my own cars because I know when I'm going to get the job done so when I have to depend on other folks I get a little stressed out as I like stuff done on time. "should be" and " don't worry" phrases bother me. When I have to schedule all my parts ordered to be in time for CR visits you can imagine I get freaked out! The ECU tune came at the last day and the LSD came with the wrong final drive! so eventually everything showed up on time. Thanks Way Motors, Gripper and Emini parts who always deliver on time. The next week are going to be mental. I have rebuilt the transmission, fit the short block and transmission. Fit the dash/heater, paint the interior and engine bay white, more welding and have all this done for dec 17th!

 

Building a rally from scratch is not easy but imagine trying to build a rally car in another country with no garage and limited equipment. Long hours and hard work get the jobs done! This week and weekend have seen the gearbox rebuilt with a LSD and 5:1 final drive. The engine checked over with a new oil pump and all new seals etc. The weekend consisted of getting the shell back from the cage installer, prepping the engine bay and interior for painting. I choose white as I think rally car looks clean with white and adds that professional touch. Masking up seemed to take forever as did degreasing and rubbing down the interior body work. I was ready to spray only to find the compressor didn’t work! Also someone had stolen the spray gun while it had sat in the shed since 2009! Lucky for me I brought my touch up low pressure gun with me so after some frantic calls I got a hobby 40psi compressor which worked perfect. It took me around 3 hours to paint the engine bay and inside the car until I ran out of paint. Tonight I should be finished the painting ready to install the heater/dash etc. I have a deadline of Dec 20th to get the Mini into customs to avoid a $500 fine and repossession of the car. All they need is the car and engine so I’ll be taking it less the gearbox/ cylinder head and all that bolts to them. A few straps should hold the short engine in place !! hahaha. I'll take some photos soon.

 

Thanks Steve it's possible to drive but the near 3 weeks trip could be an interesting experience!

 

Got the cage painted!

 

engine bay

 

Thanks chaps! The rear wing is off a Subaru Impreza WRX wagon

 

fits on the top but underneath you need some spacers and filler.

 

Here's the nearly finished dash. and the Mini in the customs jail along with all the cars no one cleared!

Amazing I did the clutch alignment by eye sight with the box fitting on perfect! Now time to relax until I get the Mini back in Mid January

 

Finally got the Mini out of the customs! Did the the wheel stud conversion on the front

 

As you know I'm using STI struts on the front and it looks likely I'll be using STI on the back. Mini damper is on the left.

The old and the new!

 

Thanks Dave, On Feb 10th I'll be off back down to CR with STI rear dampers, adjustable brake bias, Hydraulic hand brake, battery boot relocation, sadly the oringinal radiator as my WRX conversion will not be allowed in the rules plus a bunch of other stuff and decals. The goal is to have the engine running by the end of Feb. First rally date is April 14th. More photos to follow.

 

one of the most popular questions I get is to why did I go with Subaru STI for my suspension. 1/ good past experience 2/ cost 3/ gravel spec availability . There seems to be a ton of tarmac spec dampers but nothing for gravel at a cost I can afford. I'm using road dampers to start with, then could use this set up. Ksport Adjustable Coilover Systems, Camber Kits and Suspension Products | Ksport Store

 

This visit I got the cam shaft in and most of the engine parts back where they should be. With a few hours work I was able the fit the Subaru STI rear dampers to the R56 trailing arm. Work required was to make a new top mount using Subaru/Mini , bore out the bottom bolt hole to 14mm and grind a little bit off the trailing arm. Ride height went up by 3/4" and I get around 1 1/2" extra . travel. Brake line I will attach later.