Hey guys time i started a build thread on here this is my full build, from December 2008 until 23rd May, Challenge day, this car was built for the PPC £999 challenge. This is now MOT'ed and Road Legal!
Before i start and give you the brief for this i would like to make you aware that this is more of a "scrap heap challenge" using off cuts and re-cycling as much of the cars as possible, so where as most people would buy nice correct metal, we are using either what we have, found in a scrappys or what was already fitted to the cars.
So here we go:
Aims:
To build and compete in the PPC £999 Challenge
Complete a sub 10minute lap of the ring SRR09
Budget:
£999 or under
Car:
Classic Mini FREE
Toyota Mk1 Mr2 FREE
Plan:
To build a classic mini complete with toyota running gear
Target Bhp:
150
Heres the build:
Date:
22/12/2008
Money Spent
£0
Time:
20.00-1am
Work Done
1. Steam cleaned MR2
2. Brought in MR2 and removed engine and running gear
20-15 Toyota nearly Clean
21-20 Engine nearly out (honest)
00.59 (its out at last!)
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P231208_00.59[01].jpg
Hands on
Dazzler
Fartinmartin
Dangermouse (evening teaboy)
Date:
29-30/12/2008
Money Spent
£-30
Scrapman gave me £30 for the MR2
Time:
2 days in and around other jobs (5 hours total)
Work Done
1. Stripped all other bits of MR2
2. Tidied Back room out
3. Moved MR2 out
4. Moved mini in
5. Got MR2 Collected
working on the MR2 (29/12/08 12.30)
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P291208_12.30[01].jpg
Workshop tidy and engine in place ready to play(29/12/08)
Bye Bye MR2
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P301208_12.37[02].jpg
Hands on
Dazzler
Red5
jnr update
Just sat the body over the engine to see what room there is...
Subframe building tomorrow!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P301208_18.00[01].jpg
Date:
03/01/09
Work Done
Cut down subframe to check for clearances and get a general feel for position
Time
5 hours
12.41
17.02
It looks from the pics like nothing has been done, however lots of progress today, got the engine in the position where it is going to sit with suspension towers in place (std mini front cones etc), gearbox clears, pulleys clear, drive shafts will clear and fit so... Monday we will make the first mounts to hold the engine to the towers which are fitted.
For a round nose this is going need custom inlet manifold and exhaust as first thought, but for clubman the std exhaust will fit with enough room for a front mounted rad.
Date
10-11/01/09
Money Spent
£0
Project total
£-30
Time:
13hours over 2 days
Work Done
Made front subframe mk1, fitted all suspension componants, fitted to car, placed on wheels to check for clearances.
Sounds like not a lot, but honest, its loads of work!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P100109_16.41[01].jpg
Just checking, it looked good
Its in and on its wheels!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P110109_21.30[01].jpg
Hands on
Dazzler
FATLAD
Date: 23/02/2009
Time Spent: 19.30-22.30
Money Spent: £0
Total Money: - £30
Hands on: Dazzler & FartinMartin
Work Done:
So tonight we have really kicked back in, we started by making a mock up Exhuast Manifold out of toilet paper tubes, we then did something similar to the inlet to give us an idea of space etc.
We have modified the Oil Filer housing and removed the oil cooler plate
We then moved onto the Gear linkage, which i am please to tell you that from draft we have completed, all we have left to make is two cable holders which we will prob do on the car!
I only have a couple of pics which are not worth showing, however when the linkages are complete with cables i will get them up
Date: 01/03/2009
Time Spent: 11.00-18.00 today 1hour Yesterday
Money Spent: £3.90
Total Money: - £26.10
Hands on: Dazzler & FATLAD
Work Done:
Lots of bits so... heres the story starts yesterday
Well yesterday was soooooo funny we went down to the local scrappers for some tube to make the inlet from, found what we wanted went to the guy in the yellow coat
Daz "how much for this"
Man "whats it worth to you"
Daz "dunno maybe a tenner"
Man " don't be silly give me a fiver"
Daz " ok i will get me wallet, can i throw it in the van"
Man " quick get it in the van, quickly"
Daz (puts hand in pocket pulls out £3.90) "I have 4quid in change"
Man "quick give us the money and curse word off, the owner is coming"
LOL, looks like we have paid some random £3.90 for some gear from the scrappy we laughed all the way home!
Next up we have been using that steel and random pipes to make the inlet manifold
heres to pics, its not finished yet
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P010309_13.12[01].jpg
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P010309_15.20[02].jpg
jnr update
Had ten mins on it tonight, i think you get the idea how its shaping up, i will have it finished for the weekend!
Ok then two Updates
Sat & Sunday Subframe time spent: 12hours over two days
Cost: £0
Workers: Dazzler & Bleet
Removed subframe, added tie bars and strengthening also finished off the mounting point on the Gearbox side, the only thing left to do on the frame now is rear engine mount & Alternator bracket.
Also added front bar
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P150309_14.34[01].jpg
Update 2
Tonight Inlet work: Time spent 2hours
Workers: Dazzler
Cost £0
Total Cost £-26.10
Tonight i have made more progress on the inlet tomorrow i will be porting it smooth and then placing the ends on
Ok, this is a partial update the rest will come in a propper write up sometime sunday i would think with pictures and stuff
We have fitted the engine and frame back into the car and have found we need to mod the sump as it fouls the tie bar, we though the gearbox was going to catch however a quick tester with me jumping up and down on it, i am a full 18stone gave us full travel and has had the floor touching the gorund without and further probs
quick vid
Will take some pics of the sump later we are just about to start if for the night shift!
Full Update time...
So there has been lots and lots done, too much to list in my usual way, heres the shorts
i was -£26.10
I have spent:
£230 (front end, roof, boot) NOW CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
So thats £245.00, less the £26.10 (gonna call that 25 for ease)
So i am at £220 spent
Other updates, i have been given by Ives a fuel tank from a tigra complete with fuel pump, the scooby bax box is out and out of the exhaust shops "free" second hand stuff i have had a "Astra GTE back box"
So heres the pics
This is where i was upto, frame in the car back on its wheels roof cut out ready for fibre roof skin
heres the Inlet test
Then the front was cut off to make life a whole load easier while making stuff
heres the home for the alternator
The sump fouled the Tie bar, so thats been cut and modded
The inlet was taken closer to finishing
Ok, so this weekend lots done and focused on getting the body ready-er for MOT lol
free stuff is how it started
Then a big hole was cut
Then the flat floor went in
Then the exhaust was fitted for maximum ground clearance
So, the arches are tubbed the back end is low and 90% done
the only big choice i have now is do i fit the bumpers or de-seam it on the back?
Tonights update
I have been busy getting the shell ready for MOT so i have rolled the shell on its side to make it easyer, i have done repair work to the whole side of the car, finished the tubbing and the underside of the boot floor
Here it is
and another view before i start on, showing exhaust position
after several hours its now welded then seam sealed ready to do the other side tomorrow before clean and paint
Martin has been busy sorting out the loom on the engine which is complete in the frame on a pallet
Right then tonights update
Rolled it on its other side and sorted that out heres the before and after
Then a quick blanker was made for the fuel neck hole
The boot has now been completely finished and is seam sealed ready to go
So tomorrow will be working on the front of the shell i am still hoping to have this painted for the weekend then the build up can begin.
Update time:
Last night, still welding the shell, its a total shed! no pics as i was too busy, i would say i am 75% done welding the shell, this should be finished tomorrow....
I have taken tonight off welding its starting to bother me, so me and mart have turn our attention to the wiring
Had about 2 hours at it, we have go the ecu system working and starter etc so we are happy that we can make it run using the toyota fuse box, so we will be bringing the mini loom to the toyota fuse box and it will go from there
Jobs left to do
Drive Shafts (materials here monday)
Finish Shell welding
Build up for MOT
Fit roll cage
Paint shell
Wire up
Sort out cooling system
Exactly 1 month to go until the event!
Update time
Last night and today
Its all started with sorting the rot out, i will have some pics of inside tomorrow, ALL the rot is now sorted and welded and the underside of the car is now painted!!!!!
Heres the pics
Part way through
stating the degrease and clean
All clean
Stood up on its end ready for paint
And Painted
Today's Update
Shell is now Painted!!!
So its welded & Painted just the build up left
I will also do a budget update tomorrow with tomorrow nights build up work
Update time
Heres the stuff Sonia has fetched
Ok so Martin has made the driveshafts at work today (well one of them)
Heres the pic of it fitted
then we have fitted the FREE fuel tank!
then we tried the roof
then we tried the boot
Now lastly remember the exhaust we got from the exhaust mans skip, well heres a bit more of a close up, how many points do i get for "chav-tastic" add-ons?
Todays update
It started with the £50 running doner car arriving, long story short i have brought this to break for the engine for JC (my mini van) however i am missing lots for bits for the build so this will do
bonus the 50 quid car came with a nearly new battery with £49.99 on it so bargain!
Started to build up the car
Thats it now until Tuesday!
Righty, cost update
I was at £220 spent ref update 19/04/09
Things to add
Rear Valence £10
Service items for engine £68 (not fitted yet but will do)
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
Doner car £25 (as the engine is going in another car!)
So that takes me to £323 spent!
I still have to buy in (expected cost)
Dashboard (88)
Shockers (100)
Pay for MOT (35)
Seat (50)
Harness (50)
So that puts me at a forecast cost of £646
Right then update
Came in this morning to find the magic car fairys have stripped the doner car and put all the bits nicely by the mini-ota
After filling it full of scrap and two trips to the local scrap merchants i am £55 quid better off (i am not going to put that in the budget!)
Ok then, so its been build up time, its slow and boring the engine is back in the car with most the wring on, inlet is on and fitted with its new sticker
We then last thing had a look at fitting the new front on, it has to be trimmed etc but its all fits with loads of room, would have got a V8 in there!
Martin has been working on fitting the fibreglass bootlid etc, will have some more pics tomorrow
Tonights update
ok heres the Free arches, i got given these ages ago wasnt sure what do do about costing so i asked for a value and it was decided here www.minifinity.com/distribution/viewtopic.php?f=7&t=82176#p826967
Then we worked on wiring placement
we have also done other things like test the fuel pump, plumb them in to the front etc, boot lid is now trimmed and fitted etc
i took this pic to show clearance with the daz made manifold
Other things of interest today, i have ordered the dash for it, brought in dash warning LEDs and Ordered Harnesses!
Todays Update:
So today (yes day time) the car has been down to "Stafford Tyres" these guys have let me raid there skip enough already for bits for the car so i thought it was fair to send it down for a PAID job!
I have got them to make up the exhaust between the boxes i have fitted! (pics soon)
Heres the 50 quid shockers
and more bling has arrived!
Mart picked me up the Tiebars from Newark show and the dash has just arrived today!
So tonight i am busy taking the engine back out as there has been a slight oversight and the Shocker hits the subframe on the drivers side!
Update time
This is Saturday and Sunday
I will tell most the story with the pictures, however we are nearly back where we was the other day! after fitting up the subframe we found that we had made a small oversight and the shocker just hit the subframe, so we have removed it, modded it and refitted it. Also the other driveshaft has been completed by mart, the car has been built back up with "MOT" standard in mind so all nuts and bolts have been fitted and tightened, ball joints & wheel bearings checked on the front etc.
Also we have had to fix both the welder and the Grinder!!!!
So heres the pics
Long driveshaft is complete
Welding
More Welding
Had a visit of "Little Red Grinding Hood"
This is where the mod was
While it was out we have also added bits to help the frame and seamed up everywhere
We have also made extra braces to go from the body to the frame, they can just be seen in this pic
This is the top plate for them
a quick pic of the clearance down the drivers side
ok so other bits, heres the exhuast
Mart has picked up this seat today from himley a tenner!!! he says if my
is too fat for it, i can have his passenger seat from his car as a swap! happy days!
lastly it has been said on the odd forum that this build seems like a "club" effort, well its not, its just the 4 of us
From the right "Dazzler" then "FATLAD" then "Fartin Martin" then on the end "Bleety"
Update time, last night and tonight
This is how last night started, we rolled out the mini=ota to work on it outside, so state of play the front is as low as it can go (this has got to go up a little for mot)
couple of shots of the underside, this has the exhaust fitted!!!
so we made a start fitting the fibre front, we did this from taking a measurement of marts car then working out his sill height to mine and then applying the diff to work out where the nose needs to be
we then checked the seat and i am too fat, so the one behind mart will be the one in the car, he has swapped it for the ten quid seat, which is a better seat FFS! i have been stitched up!
today/tonight
Gear linkages, didnt have any that would work so made some!!
this is the top one
Thats them fitted to the car, for some reason i havent took any pics of the lower one, but its made fairly the same
then we have had to sort out the alternator and belt position, FATLAD has done a right bodge of the tensioner, although it has worked to test if the belt will stay on, i will make a better one tomorrow!
lastly tonight we have moved on to get it running, man did we make a wrong assumption over the wiring
I was not a happy bunny!!
But in the end (about 2 hours) found the problem with the ecu not giving signal to keep the spark up, fixed it, put some fuel in and we was away....... kinda..... it went bbbbaaaaaarrrrrrrpppppppp but it didnt rev or run well.... 20 mins later we relaised we had had the dissy off and the timing "might" be out, a quick twist and a secong start and it was away.... MINT
20:09 on 12th May 2009 the Mini-Ota is ALIVE!!!!!!!!
Today/tonight update
Panel work is now 90% and the rad mount is made and fitted, as is modded front brace
Cooling pipes in place with a mix of mini and toyota hoses 1 random hose that was in my box and some galv tube, the rad mount is made from some old shelving! this ofcourse would have been better with nice box or angle but we wasnt going to spend the money so we recycled!
heres the pics of the front 90% sorted
John with the free pipe from the metal merchants (JS Metals Stafford)
Free pipe on the car
The rad mount
At this point we had tea with a Cobra! and we thought minis and toyotas was a good combo, we was wrong Meat Balls, mince and taters are the way!
Back to the rad mount
And the finish job!
Another big day tomorrow!
cost update (this is what i have submitted)
"Costs:
£50 (Nominal cost) Mini was actually free
£50 (Nominal cost) MR2 was actually Free
£3.90 Misc metal for inlet etc
£230 (front end, roof, boot) CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
£10 Rear Valence
£68 Service items for engine
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
£25 Doner (mini as seen in build) car
£89 Dashboard
£50 second hand gaz shockers
£40 MOT (not been yet!)
£10 Seat
£19.50 Harness
£25 Adjustable Tie Bars
£50 Exhaust
£80 Wheels
Total Spent to date
£815.40
Money back in to date
£30 for scrap from the remains of the MR2
Cost of build
£785.40
(i haven’t included in the cost consumables & welding wire etc, but i would estimate total consumable cost at £50)"
don't think i have missed anything?
Update time:
Body mount
Final version of moved/modded rad mount
Pushed out for some sunlight! body is mounted and started to build up!
at one point today there was 4 of us working on the mini-ota
John building the front up
Heavy duty rad stablizer lol
Early throttle cable holder
here it is in action
the engine bay is starting to take shape
Heres the start of the battery box, made from more old shelving and some plastic offcut stuff
Other things of interest the clutch is done and is fully working, most the pipe work is in place, tomorrow it should be holding water, able to start of the key and not just twisted together wires and should be able to drive it out the unit!!!!!
Sunday is wiring day
Aiming for a monday morning MOT!
Right then another no picture update
I got as far as the first on the list, we now havew the engine running as well as it did in the MR2 (which was failry poo poo) we thought that a service on it would sort it but so far it hasnt, there is major fueling/smoking issues too much so that it wont pass its MOT. So today through a friend of a man with a dog, who knows someone down the pub i have been able to source a spare 4AGE engine complete with injectors etc just incase.
At the moment we think its just a stuck injector, however there is also a knock in there too, so we may well change the engine, as to take off the inlet to get to the injectors, the engine has to come out the frame.
So, not running, no MOT and 3 days available to get a MOT!
Ok then guys, last of tonights updates, it has gone well so we are optioning for sleep
we still have a couple of days, lol, loadsa time
heres the first start with water in
this is a couple of mins after when idle has settled and its warmed a bit
will do a cost update tomorrow if/when i get time
Pictures will have to prob come after event now, as i don't think i will have time
I have a few things to add to that
£50 Engine
£15 Dash lights & switches
£30 Misc Pipe
£10 End of world switch
I had put a Costing in for £50 for the MR2, as the rules say i should, however it was given to me, and it turns out the engine was fudged, so make your own mind up over that and if to keep it in cost.
So i make that £890.40
Ok then the final missing bits from the update:
dashboard, this was made from some £1 Leds from maplin, and some fibreglass left over from the front end
heres the pics
Fuel tank was made from an old knackered van fuel tank and some of the free scrap pipe, heres the pics
here it is in the car finished
we also had to do a last minute engine change in the last few days before the event, while the engine was out i did a bit more to the subframe
new engine in the frame, this picture was taken 23.55 on the 19th May!
i also needed to mod the cam cover so the pulleys were not exposed, bu the alternator would fit
we then finished putting it together to get an MOT, we very nearly missed the last MOT apointment before the event, it was 14.00 on the 22nd, we got there at 14.06! close!
so it passed its MOT at 15.01 on the 22nd May
we then got it finished for the event
and finally at 22.30 22nd May loaded it on the trailer ready to set off to mallory park
Heres some pictures taken of it on the day in action
so then is the build over... well far from it, we didnt get time to paint the doors or finish inside properly, the new engine got goosed on its 8th/9th lap in an open session so there will be the new engine to go on, prob with a turbo or nos!
Before i start and give you the brief for this i would like to make you aware that this is more of a "scrap heap challenge" using off cuts and re-cycling as much of the cars as possible, so where as most people would buy nice correct metal, we are using either what we have, found in a scrappys or what was already fitted to the cars.
So here we go:
Aims:
To build and compete in the PPC £999 Challenge
Complete a sub 10minute lap of the ring SRR09
Budget:
£999 or under
Car:
Classic Mini FREE
Toyota Mk1 Mr2 FREE
Plan:
To build a classic mini complete with toyota running gear
Target Bhp:
150
Heres the build:
Date:
22/12/2008
Money Spent
£0
Time:
20.00-1am
Work Done
1. Steam cleaned MR2
2. Brought in MR2 and removed engine and running gear
20-15 Toyota nearly Clean
21-20 Engine nearly out (honest)
00.59 (its out at last!)
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P231208_00.59[01].jpg
Hands on
Dazzler
Fartinmartin
Dangermouse (evening teaboy)
Date:
29-30/12/2008
Money Spent
£-30
Scrapman gave me £30 for the MR2
Time:
2 days in and around other jobs (5 hours total)
Work Done
1. Stripped all other bits of MR2
2. Tidied Back room out
3. Moved MR2 out
4. Moved mini in
5. Got MR2 Collected
working on the MR2 (29/12/08 12.30)
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P291208_12.30[01].jpg
Workshop tidy and engine in place ready to play(29/12/08)
Bye Bye MR2
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P301208_12.37[02].jpg
Hands on
Dazzler
Red5
jnr update
Just sat the body over the engine to see what room there is...
Subframe building tomorrow!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P301208_18.00[01].jpg
Date:
03/01/09
Work Done
Cut down subframe to check for clearances and get a general feel for position
Time
5 hours
12.41
17.02
It looks from the pics like nothing has been done, however lots of progress today, got the engine in the position where it is going to sit with suspension towers in place (std mini front cones etc), gearbox clears, pulleys clear, drive shafts will clear and fit so... Monday we will make the first mounts to hold the engine to the towers which are fitted.
For a round nose this is going need custom inlet manifold and exhaust as first thought, but for clubman the std exhaust will fit with enough room for a front mounted rad.
Date
10-11/01/09
Money Spent
£0
Project total
£-30
Time:
13hours over 2 days
Work Done
Made front subframe mk1, fitted all suspension componants, fitted to car, placed on wheels to check for clearances.
Sounds like not a lot, but honest, its loads of work!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P100109_16.41[01].jpg
Just checking, it looked good
Its in and on its wheels!
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P110109_21.30[01].jpg
Hands on
Dazzler
FATLAD
Date: 23/02/2009
Time Spent: 19.30-22.30
Money Spent: £0
Total Money: - £30
Hands on: Dazzler & FartinMartin
Work Done:
So tonight we have really kicked back in, we started by making a mock up Exhuast Manifold out of toilet paper tubes, we then did something similar to the inlet to give us an idea of space etc.
We have modified the Oil Filer housing and removed the oil cooler plate
We then moved onto the Gear linkage, which i am please to tell you that from draft we have completed, all we have left to make is two cable holders which we will prob do on the car!
I only have a couple of pics which are not worth showing, however when the linkages are complete with cables i will get them up
Date: 01/03/2009
Time Spent: 11.00-18.00 today 1hour Yesterday
Money Spent: £3.90
Total Money: - £26.10
Hands on: Dazzler & FATLAD
Work Done:
Lots of bits so... heres the story starts yesterday
Well yesterday was soooooo funny we went down to the local scrappers for some tube to make the inlet from, found what we wanted went to the guy in the yellow coat
Daz "how much for this"
Man "whats it worth to you"
Daz "dunno maybe a tenner"
Man " don't be silly give me a fiver"
Daz " ok i will get me wallet, can i throw it in the van"
Man " quick get it in the van, quickly"
Daz (puts hand in pocket pulls out £3.90) "I have 4quid in change"
Man "quick give us the money and curse word off, the owner is coming"
LOL, looks like we have paid some random £3.90 for some gear from the scrappy we laughed all the way home!
Next up we have been using that steel and random pipes to make the inlet manifold
heres to pics, its not finished yet
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P010309_13.12[01].jpg
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P010309_15.20[02].jpg
jnr update
Had ten mins on it tonight, i think you get the idea how its shaping up, i will have it finished for the weekend!
Ok then two Updates
Sat & Sunday Subframe time spent: 12hours over two days
Cost: £0
Workers: Dazzler & Bleet
Removed subframe, added tie bars and strengthening also finished off the mounting point on the Gearbox side, the only thing left to do on the frame now is rear engine mount & Alternator bracket.
Also added front bar
www.staffsminis.co.uk/images/phocagallery/dazzler-dazzlers-p-8cc8/thumbs/phoca_thumb_l_P150309_14.34[01].jpg
Update 2
Tonight Inlet work: Time spent 2hours
Workers: Dazzler
Cost £0
Total Cost £-26.10
Tonight i have made more progress on the inlet tomorrow i will be porting it smooth and then placing the ends on
Ok, this is a partial update the rest will come in a propper write up sometime sunday i would think with pictures and stuff
We have fitted the engine and frame back into the car and have found we need to mod the sump as it fouls the tie bar, we though the gearbox was going to catch however a quick tester with me jumping up and down on it, i am a full 18stone gave us full travel and has had the floor touching the gorund without and further probs
quick vid
Will take some pics of the sump later we are just about to start if for the night shift!
Full Update time...
So there has been lots and lots done, too much to list in my usual way, heres the shorts
i was -£26.10
I have spent:
£230 (front end, roof, boot) NOW CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
So thats £245.00, less the £26.10 (gonna call that 25 for ease)
So i am at £220 spent
Other updates, i have been given by Ives a fuel tank from a tigra complete with fuel pump, the scooby bax box is out and out of the exhaust shops "free" second hand stuff i have had a "Astra GTE back box"
So heres the pics
This is where i was upto, frame in the car back on its wheels roof cut out ready for fibre roof skin
heres the Inlet test
Then the front was cut off to make life a whole load easier while making stuff
heres the home for the alternator
The sump fouled the Tie bar, so thats been cut and modded
The inlet was taken closer to finishing
Ok, so this weekend lots done and focused on getting the body ready-er for MOT lol
free stuff is how it started
Then a big hole was cut
Then the flat floor went in
Then the exhaust was fitted for maximum ground clearance
So, the arches are tubbed the back end is low and 90% done
the only big choice i have now is do i fit the bumpers or de-seam it on the back?
Tonights update
I have been busy getting the shell ready for MOT so i have rolled the shell on its side to make it easyer, i have done repair work to the whole side of the car, finished the tubbing and the underside of the boot floor
Here it is
and another view before i start on, showing exhaust position
after several hours its now welded then seam sealed ready to do the other side tomorrow before clean and paint
Martin has been busy sorting out the loom on the engine which is complete in the frame on a pallet
Right then tonights update
Rolled it on its other side and sorted that out heres the before and after
Then a quick blanker was made for the fuel neck hole
The boot has now been completely finished and is seam sealed ready to go
So tomorrow will be working on the front of the shell i am still hoping to have this painted for the weekend then the build up can begin.
Update time:
Last night, still welding the shell, its a total shed! no pics as i was too busy, i would say i am 75% done welding the shell, this should be finished tomorrow....
I have taken tonight off welding its starting to bother me, so me and mart have turn our attention to the wiring
Had about 2 hours at it, we have go the ecu system working and starter etc so we are happy that we can make it run using the toyota fuse box, so we will be bringing the mini loom to the toyota fuse box and it will go from there
Jobs left to do
Drive Shafts (materials here monday)
Finish Shell welding
Build up for MOT
Fit roll cage
Paint shell
Wire up
Sort out cooling system
Exactly 1 month to go until the event!
Update time
Last night and today
Its all started with sorting the rot out, i will have some pics of inside tomorrow, ALL the rot is now sorted and welded and the underside of the car is now painted!!!!!
Heres the pics
Part way through
stating the degrease and clean
All clean
Stood up on its end ready for paint
And Painted
Today's Update
Shell is now Painted!!!
So its welded & Painted just the build up left
I will also do a budget update tomorrow with tomorrow nights build up work
Update time
Heres the stuff Sonia has fetched
Ok so Martin has made the driveshafts at work today (well one of them)
Heres the pic of it fitted
then we have fitted the FREE fuel tank!
then we tried the roof
then we tried the boot
Now lastly remember the exhaust we got from the exhaust mans skip, well heres a bit more of a close up, how many points do i get for "chav-tastic" add-ons?
Todays update
It started with the £50 running doner car arriving, long story short i have brought this to break for the engine for JC (my mini van) however i am missing lots for bits for the build so this will do
bonus the 50 quid car came with a nearly new battery with £49.99 on it so bargain!
Started to build up the car
Thats it now until Tuesday!
Righty, cost update
I was at £220 spent ref update 19/04/09
Things to add
Rear Valence £10
Service items for engine £68 (not fitted yet but will do)
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
Doner car £25 (as the engine is going in another car!)
So that takes me to £323 spent!
I still have to buy in (expected cost)
Dashboard (88)
Shockers (100)
Pay for MOT (35)
Seat (50)
Harness (50)
So that puts me at a forecast cost of £646
Right then update
Came in this morning to find the magic car fairys have stripped the doner car and put all the bits nicely by the mini-ota
After filling it full of scrap and two trips to the local scrap merchants i am £55 quid better off (i am not going to put that in the budget!)
Ok then, so its been build up time, its slow and boring the engine is back in the car with most the wring on, inlet is on and fitted with its new sticker
We then last thing had a look at fitting the new front on, it has to be trimmed etc but its all fits with loads of room, would have got a V8 in there!
Martin has been working on fitting the fibreglass bootlid etc, will have some more pics tomorrow
Tonights update
ok heres the Free arches, i got given these ages ago wasnt sure what do do about costing so i asked for a value and it was decided here www.minifinity.com/distribution/viewtopic.php?f=7&t=82176#p826967
Then we worked on wiring placement
we have also done other things like test the fuel pump, plumb them in to the front etc, boot lid is now trimmed and fitted etc
i took this pic to show clearance with the daz made manifold
Other things of interest today, i have ordered the dash for it, brought in dash warning LEDs and Ordered Harnesses!
Todays Update:
So today (yes day time) the car has been down to "Stafford Tyres" these guys have let me raid there skip enough already for bits for the car so i thought it was fair to send it down for a PAID job!
I have got them to make up the exhaust between the boxes i have fitted! (pics soon)
Heres the 50 quid shockers
and more bling has arrived!
Mart picked me up the Tiebars from Newark show and the dash has just arrived today!
So tonight i am busy taking the engine back out as there has been a slight oversight and the Shocker hits the subframe on the drivers side!
Update time
This is Saturday and Sunday
I will tell most the story with the pictures, however we are nearly back where we was the other day! after fitting up the subframe we found that we had made a small oversight and the shocker just hit the subframe, so we have removed it, modded it and refitted it. Also the other driveshaft has been completed by mart, the car has been built back up with "MOT" standard in mind so all nuts and bolts have been fitted and tightened, ball joints & wheel bearings checked on the front etc.
Also we have had to fix both the welder and the Grinder!!!!
So heres the pics
Long driveshaft is complete
Welding
More Welding
Had a visit of "Little Red Grinding Hood"
This is where the mod was
While it was out we have also added bits to help the frame and seamed up everywhere
We have also made extra braces to go from the body to the frame, they can just be seen in this pic
This is the top plate for them
a quick pic of the clearance down the drivers side
ok so other bits, heres the exhuast
Mart has picked up this seat today from himley a tenner!!! he says if my
is too fat for it, i can have his passenger seat from his car as a swap! happy days!lastly it has been said on the odd forum that this build seems like a "club" effort, well its not, its just the 4 of us
From the right "Dazzler" then "FATLAD" then "Fartin Martin" then on the end "Bleety"
Update time, last night and tonight
This is how last night started, we rolled out the mini=ota to work on it outside, so state of play the front is as low as it can go (this has got to go up a little for mot)
couple of shots of the underside, this has the exhaust fitted!!!
so we made a start fitting the fibre front, we did this from taking a measurement of marts car then working out his sill height to mine and then applying the diff to work out where the nose needs to be
we then checked the seat and i am too fat, so the one behind mart will be the one in the car, he has swapped it for the ten quid seat, which is a better seat FFS! i have been stitched up!
today/tonight
Gear linkages, didnt have any that would work so made some!!
this is the top one
Thats them fitted to the car, for some reason i havent took any pics of the lower one, but its made fairly the same
then we have had to sort out the alternator and belt position, FATLAD has done a right bodge of the tensioner, although it has worked to test if the belt will stay on, i will make a better one tomorrow!
lastly tonight we have moved on to get it running, man did we make a wrong assumption over the wiring
I was not a happy bunny!!
But in the end (about 2 hours) found the problem with the ecu not giving signal to keep the spark up, fixed it, put some fuel in and we was away....... kinda..... it went bbbbaaaaaarrrrrrrpppppppp but it didnt rev or run well.... 20 mins later we relaised we had had the dissy off and the timing "might" be out, a quick twist and a secong start and it was away.... MINT
20:09 on 12th May 2009 the Mini-Ota is ALIVE!!!!!!!!
Today/tonight update
Panel work is now 90% and the rad mount is made and fitted, as is modded front brace
Cooling pipes in place with a mix of mini and toyota hoses 1 random hose that was in my box and some galv tube, the rad mount is made from some old shelving! this ofcourse would have been better with nice box or angle but we wasnt going to spend the money so we recycled!
heres the pics of the front 90% sorted
John with the free pipe from the metal merchants (JS Metals Stafford)
Free pipe on the car
The rad mount
At this point we had tea with a Cobra! and we thought minis and toyotas was a good combo, we was wrong Meat Balls, mince and taters are the way!
Back to the rad mount
And the finish job!
Another big day tomorrow!
cost update (this is what i have submitted)
"Costs:
£50 (Nominal cost) Mini was actually free
£50 (Nominal cost) MR2 was actually Free
£3.90 Misc metal for inlet etc
£230 (front end, roof, boot) CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
£10 Rear Valence
£68 Service items for engine
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
£25 Doner (mini as seen in build) car
£89 Dashboard
£50 second hand gaz shockers
£40 MOT (not been yet!)
£10 Seat
£19.50 Harness
£25 Adjustable Tie Bars
£50 Exhaust
£80 Wheels
Total Spent to date
£815.40
Money back in to date
£30 for scrap from the remains of the MR2
Cost of build
£785.40
(i haven’t included in the cost consumables & welding wire etc, but i would estimate total consumable cost at £50)"
don't think i have missed anything?
Update time:
Body mount
Final version of moved/modded rad mount
Pushed out for some sunlight! body is mounted and started to build up!
at one point today there was 4 of us working on the mini-ota
John building the front up
Heavy duty rad stablizer lol
Early throttle cable holder
here it is in action
the engine bay is starting to take shape
Heres the start of the battery box, made from more old shelving and some plastic offcut stuff
Other things of interest the clutch is done and is fully working, most the pipe work is in place, tomorrow it should be holding water, able to start of the key and not just twisted together wires and should be able to drive it out the unit!!!!!
Sunday is wiring day
Aiming for a monday morning MOT!
Right then another no picture update
I got as far as the first on the list, we now havew the engine running as well as it did in the MR2 (which was failry poo poo) we thought that a service on it would sort it but so far it hasnt, there is major fueling/smoking issues too much so that it wont pass its MOT. So today through a friend of a man with a dog, who knows someone down the pub i have been able to source a spare 4AGE engine complete with injectors etc just incase.
At the moment we think its just a stuck injector, however there is also a knock in there too, so we may well change the engine, as to take off the inlet to get to the injectors, the engine has to come out the frame.
So, not running, no MOT and 3 days available to get a MOT!
Ok then guys, last of tonights updates, it has gone well so we are optioning for sleep
we still have a couple of days, lol, loadsa time
heres the first start with water in
this is a couple of mins after when idle has settled and its warmed a bit
will do a cost update tomorrow if/when i get time
Pictures will have to prob come after event now, as i don't think i will have time
cost update (this is what i have submitted)
"Costs:
£50 (Nominal cost) Mini was actually free
£50 (Nominal cost) MR2 was actually Free
£3.90 Misc metal for inlet etc
£230 (front end, roof, boot) CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
£10 Rear Valence
£68 Service items for engine
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
£25 Doner (mini as seen in build) car
£89 Dashboard
£50 second hand gaz shockers
£40 MOT (not been yet!)
£10 Seat
£19.50 Harness
£25 Adjustable Tie Bars
£50 Exhaust
£80 Wheels
Total Spent to date
£815.40
Money back in to date
£30 for scrap from the remains of the MR2
Cost of build
£785.40
"Costs:
£50 (Nominal cost) Mini was actually free
£50 (Nominal cost) MR2 was actually Free
£3.90 Misc metal for inlet etc
£230 (front end, roof, boot) CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing
£10 Rear Valence
£68 Service items for engine
Paint was free (long story if anybody wants to hear it, but cheers Jawell)
£25 Doner (mini as seen in build) car
£89 Dashboard
£50 second hand gaz shockers
£40 MOT (not been yet!)
£10 Seat
£19.50 Harness
£25 Adjustable Tie Bars
£50 Exhaust
£80 Wheels
Total Spent to date
£815.40
Money back in to date
£30 for scrap from the remains of the MR2
Cost of build
£785.40
I have a few things to add to that
£50 Engine
£15 Dash lights & switches
£30 Misc Pipe
£10 End of world switch
I had put a Costing in for £50 for the MR2, as the rules say i should, however it was given to me, and it turns out the engine was fudged, so make your own mind up over that and if to keep it in cost.
So i make that £890.40
Ok then the final missing bits from the update:
dashboard, this was made from some £1 Leds from maplin, and some fibreglass left over from the front end
heres the pics
Fuel tank was made from an old knackered van fuel tank and some of the free scrap pipe, heres the pics
here it is in the car finished
we also had to do a last minute engine change in the last few days before the event, while the engine was out i did a bit more to the subframe
new engine in the frame, this picture was taken 23.55 on the 19th May!
i also needed to mod the cam cover so the pulleys were not exposed, bu the alternator would fit
we then finished putting it together to get an MOT, we very nearly missed the last MOT apointment before the event, it was 14.00 on the 22nd, we got there at 14.06! close!
so it passed its MOT at 15.01 on the 22nd May
we then got it finished for the event
and finally at 22.30 22nd May loaded it on the trailer ready to set off to mallory park
Heres some pictures taken of it on the day in action
so then is the build over... well far from it, we didnt get time to paint the doors or finish inside properly, the new engine got goosed on its 8th/9th lap in an open session so there will be the new engine to go on, prob with a turbo or nos!
.. 
but go mad. Something light, V6 on throttle bodies in the back. mmmm
What a superb read, thankyou. Utter respect to all 4 of you.
