Frankenstein

[Vinay-RS]

Geez, has it really been two years since this clubby was last running and driving? That is insane. I suppose free time is at a premium at the moment with exams and work, making it difficult to get the car sorted.

[Jared Mk3]

What's needed to get the car back on the road?

[DomMINIque]

Geez, has it really been two years since this clubby was last running and driving? That is insane. I suppose free time is at a premium at the moment with exams and work, making it difficult to get the car sorted.

Yep Jacaranda run of 2017 basically was the last time it was running decently.
Got the heating issue sorted shortly after and then broke the exhaust.

And yep 100% correct working hours have gotten worse and even less free time with my exam.

What's needed to get the car back on the road?

Carb back on and set.
Exhaust fitted (after breaking at the join to the manifold)
Resolve water leak from thermostat housing.

So not too much - made the list as simple as possible to keep motivation up and cover it in bite size chunks rather than everything at once.

[DomMINIque]

So finally got a chance to work on the car this past weekend.
Didn't take any photos unfortunately, not that there was much to take photos of.

After putting the whole intake and exhaust assembly to get the car running.

I jacked it up to put on jack stands to allow me some space to reinstall the exhaust.
The manifold was still touching so called it a day, tired of fighting with the manifold, universal joint and remote shifting mechanism which all seem to be in the way.

Reverted to the old exhaust - put a standard cast manifold back on, got the exhaust clamped to the manifold. Fitted the carb and tightened everything on. And turns out the elbow I have for the standard airbox has a welded rod on to extend the bolt and now the airbox doesn't fit.

So I'm on the hunt for a new elbow and wing nut for the airbox.
In the mean time my brake pedal also goes to the floor so there is definitely a leak somewhere - I've previously almost replaced the whole system so will continue replacing what I haven't replaced and then re bleed the brakes.

1 step forward and 2 steps back at this stage but we carry on none the less.

[Vinay-RS]

That does sound frustrating, but at least you're slowly replacing all the dodgy parts. Eventually, there won't be any dodgy parts left to replace and the car will run well. (At least that is what I tell myself )

[jimmyjamjar]

can you send a pic of the elbow I might have one but not sure if its the one you need

[DomMINIque]

Sure Jimmy I'll take a photo and upload it.

So I had the opportunity to work on the car yesterday evening.
Decided to solve the leaking brake system, I am just going to change all the old bits I hadn't changed the last time I worked on the system.

So did the rear right wheel cylinder and brake line yesterday.
Low and behold, found the leak - wheel cylinder seal was gone and had the slightest leak which pooled in the bottom of the drop and hence I could never find it.

Ran out of sunlight so, just need to center the brake shoes and put the drum back on.

Then it's on to the front wheel cylinder's - need to change 3 of the 4 if I remember correctly.

[DomMINIque]

Spent a few days working from home, so saved some serious time due to not having to sit in traffic to and from work which was absolutely blissful.

Rushed out to work on the mini while the sun was still out.

And we are almost at a running driving car again.
Just two more crucial things to sort out:
1. Brakes - there still appears to be a bubble stuck inside the system somewhere.
2. Thermostat leak.

So managed to continue replacing all the other brake parts, turns out one of the front wheel cylinders was also seized - explains why under hard braking the car would pull to the side. Glad I found that and happy about my decision to replace almost the whole braking system at this point.

Tried bleeding the system, but this is a very very difficult task to do alone. I seemed to have successfully have gotten most of the air bubbles out except one, which we guess may be stuck behind the bias valve.
I continued and continued but to no avail could I get it right.

I also finally changed the gaskets and seals under the clutch and brake master cylinders as the minute it rained or the car got washed, water would appear under the pedals.
That is now resolved.

While doing this, it turns out that the engine bushings needed to be replaced (one not even being a bushing but rather a solid piece of plastic which had be jammed in). Put 2 new proper bushings in and tighten the everything back up.

Also had bought a new clutch master cylinder line to replace the concoction which was in my car - turns out the concoction is there because the slave cylinder is not actually a mini item... So that job was scrapped.

Took a few pictures and a vid this time around.

2018-09-13_01-15-51 by Dominique Bernardino, on Flickr

Parcel arrived for me during the week.

20180923_140331 by Dominique Bernardino, on Flickr

Me trying to bleed to brakes and force the bubble to the "top/rear" of the system.

20180922_155844 by Dominique Bernardino, on Flickr

Got some stickers to put on the car. They'll go on after the car gets a wash before it's first drive again after a very very long time.

20180921_121203 by Dominique Bernardino, on Flickr

Had a mate ask me if I was ever going to fit 13" wheels to the clubby so tried the set out I had at home. Don't look bad, may do it at some point with a golf conversion.

20180921_121047 by Dominique Bernardino, on Flickr

Definitely needs a spacer.

20180921_121040 by Dominique Bernardino, on Flickr

Probably some larger arches also needed.

20180923_143131 by Dominique Bernardino, on Flickr

She idles. . (The above is a video, no idea why it doesn't display as such.)

@Jimmy, sorted my carb elbow out, thanks man. Just changed the order of installation which is a little annoying but it shall work for now.

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So in summary at this point I have:

1. Replaced all the wheel cylinders and rubber hoses on the car. (also has a new master from previous work)
2. Replaced all the gaskets and sorted out the leak on the master cylinder.
3. Installed new choke and accelerator cables.
4. Replaced the jet on the hs4 and got the car running and idling again.
5. Installed a bonnet prop rod so I no longer have to use a mop to hold the bonnet up.
6. Tightened the petrol tank down as there was never a bolt there before.
7. Changed all the breather pipes and caps to new items so that the motor can breathe as it was initially intended

Still to complete:
1. Remove air bubble from brake system.
2. Change thermostat housing to Metro type, plumb expansion tank in and flush and re-bleed cooling system.
3. Install sound deadening and carpet set with gear lever gaiter.
4. Replace headlights
5. Install new boot lid cables.
6. Work on a neat and reasonable sound install.

I'm sure the list will grow as it usually does with minis.
But we carry on, the light at the end of the tunnel is a little bit bigger now.

[Vinay-RS]

That's good progress. I really like 10" wheels, but those 13s look really good too. I'm sure you could get some spaced rear drums and perhaps look at the golf discs for the front.

[Jared Mk3]

Glad the parcel got to you safely! I think this is the perfect candidate for 13" wheels, especially those ones What headlights are you going to be fitting?