Old skool Rover Sport

[Francois]

Francois was that the starting point for the rover sport build?! Wow, you have come a long way. I absolutely love the attention to detail on all of your builds. Anyone building a mini should strive for similar levels of quality.

Hey Vinay,

Yep this is how we started out with the Rover. Obviously had the whole history on the old forum and now trying to replicate as I'm finally nearing completion.

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In order to do a proper rebuild I decided to strip the car completely for shot blasting. It still amazes me how quickly one can take apart a Mini but how long it takes putting it all back together!!











And with that the shell was sent off to Environmental Sand Blasting In Epping Industrial for shot blasting.

[Miniac]

That actually wasn't a half bad looking mini you started with.

[Francois]

Whilst waiting for the shell to be shot blasted we got on with mechanical work. I opted for 8.4" disks derived from a GTS. Naturally it was completely rebuilt with new Timken bearings, ball joints, new caliper pistons and seals. The existing disks were still of a good enough thickness to re-use with a light skim.

The brake equalizer was re-sleeved and fitted with new seals.

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That actually wasn't a half bad looking mini you started with.

In hindsight no she wasn't so bad. Still we had a vision.......

[Francois]

Front sub frame was sent in for shot blasting and powder coated in black before being completely rebuilt.

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Shot blasting revealed a couple of things;

The mini was all colors of the rainbow before and the floor was VROT!!! The rear parcel shelf was also hacked to pieces and required replacement.

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We finally got the shell back to the panel beaters in Montague Gardens where the extensive surgery would commence.

As soon as the bare shell arrived it was cleaned and primed in order to prevent it from rusting.

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It is all about priorities I'm afraid - Rover Sport wheel arch fitment takes president.

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Having found a Clubman with a almost perfect floor and absolutely NO rust we set about removing both floors. This was one mammoth task as each and every spot weld had to be drilled out before the seam could be split. What seemed to be days later and with a magnitude of 6mm drill bits later Jared managed to drill all the spot welds out.

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Transplant in progress......

[Francois]

Enter donor Mini no.2 - we needed to replace the front panel on our car as it was butchered and not worth repairing. More cutting and welding.....

[Francois]

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Yes there was a 3rd donor car that was actually cut up at Brandon in Woodstock. I managed to source from here a perfect rear parcel shelf. More cutting and welding....

Out with the old,



and in with the new.










Wheel arches had to be cut back to accommodate the 13" Rover Sport wheels.






Back to Environmental Sandblasting she goes for the "new" bits to be shot blasted.

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With the shell back at Environmental Sandblasting we could concentrate on mechanical items once more;

The GTS DAM5626 gearbox was fully rebuilt by Gearbox Specialists in Goodwood. New lay shaft, new hulk rings and a complete bearing kit and we are as good as new;







New head stud set from Sport Car Center in Johannesburg;

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Time to move onto the rear sub frame;

Stripped and ready to go of for shot blasting and powder coating;



Remaining bits for refurbishment;



Back from powder coating;




Rear swing arm rebuilt with new Timken wheel bearings;



New Grabiel shock absorbers;



New washers, nuts and bolts - everywhere;



New metal brake lines made to sample by Brake Super Service in Cape Town;

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Rear brakes;

I opted for the GTS / Cooper S rear drums with the built in spacer. This will ensure that the wheels are in line with the front wheel offset thanks to the disks used. Drums were skimmed, shoes were re bonded and new brake cylinders were installed;

[Francois]

Body preparation;

I wanted as little as possible body filler on the car and they spent hours heating, shrinking and old skool panel beating the panels into shape;

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Under body preperation;

The underside was also shot blasted and required primer and rubberizing;

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Rubberizing inside;

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Final preparation before paint;

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Final, final preparation before paint;

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Rover Sport Tahiti blue is the color and we just love the end result;

[Francois]

Painted - before polish;

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Happy days!! Collecting from panel beater and going home;

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In the mean time we fitted the engine to the front sub frame ready for the body to fit over;

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Assembling!! Body lifted over front sub frame and fastened, rear end lifted and sub frame pushed in underneath;

New steering rack;







New fuel and brake lines;



Fastening bulkhead mountings;

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Fitting rear sub frame;

[Francois]

With the front sub frame fitted we moved on to fitting the rear sub frame;







On its own 4 wheels!;

[Jared Mk3]

Love the colour of this car!