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Thread: Mini rebuild and rally build

  1. #1
    Spanner Monkey Arwel's Avatar

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    Mini rebuild and rally build

    Hi all, I’m back after a few years away. Some of you may remember my previous builds, the 205 GTI rally car and a Fiesta St. I’m back now with not 1 but 2 projects. The first of these is this. It’s a 1985 Mini Mayfair that I originally owned for a brief period when I was 18. I sold it to a guy in Liverpool and I managed to track it down and buy it back in September 2019.

    The car itself wasn't a bog standard Mayfair. It has a 1275 MG Metro engine and box, spax suspension, MG Metro 4 pots, 13" minilites and had been fully de-seemed. Now, all this was done before I originally bought it in 2005, add in the fact its been sat outside since 2006 until I re acquired it in 2019, its safe to say that pretty much everything needs to be replaced. Since its going to be re born as a historic rally car, everything will need to be replaced anyway so its a perfect base to start with.

    The plan and the story so far is a full rebuild after finding copious amounts of rust, as you’ll see, and then building it as a historic spec rally car. I’ll let the pictures do the talking but so far it’s been fully stripped, the driver side sill/floor/door step has been replaced and the heel board repaired. Panels are on order to do the same on the passenger side and also replace the quarter panel.
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    Last edited by Arwel; 10-01-2021 at 17:02.

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  3. #2
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    Re: Mini rebuild and rally build

    cool, looks like you have your work cut out, nice to see something different too

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    Spanner Monkey Arwel's Avatar

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    Re: Mini rebuild and rally build

    Don't you just love two parcels full of panels being delivered. I should have everything I need here to get on with the passenger side so hopefully I can get in the garage this week and get cracking.
    Attached Thumbnails Attached Thumbnails Mini parcel.jpg‎  

    Mini parcel 2.jpg‎  

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Mini rebuild and rally build

    good thing about minis is panel prices

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    Spanner Monkey Arwel's Avatar

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    Re: Mini rebuild and rally build

    Most definitely...I would hate to think what I would have to spend if this was a mk2 Escort
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    Racer Decade Plus User mexicotait's Avatar

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    Re: Mini rebuild and rally build

    I’m on the lookout for a mini at the minute

    Not that I’m anywhere near getting my escort finish
    Hexham and District Motorclub

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    Re: Mini rebuild and rally build

    looking at your car you have your work cut out but less you know its all your own work at the end of it and thats the fun part
    sideways is the best way to turn a corner

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    Re: Mini rebuild and rally build

    Ohh tell me about it. When I initially saw it, I thought it wasn’t too bad. When I started going at it with a wire wheel, it just got worse and worse. I really do think it’s just the roof that won’t need major surgery. Before this I’d not welded anything other than an exhaust so it’s a massive learning curve but I’m getting there and the satisfaction when it’s all done will be well worth it.
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    Re: Mini rebuild and rally build

    make sure you try and test the door gaps when you are welding it up or you can loose the door gap with the shell going out of shape that will open up a big can of worms when you come up to fitting the a pannel to the front wing
    sideways is the best way to turn a corner

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    Re: Mini rebuild and rally build

    Managed to get a little time to sort the garage a bit and make some room. Managed to get the new panels roughly lined up to see where I’m cutting so I can get cracking over the weekend.
    Attached Thumbnails Attached Thumbnails 1C844CDF-918A-42DB-8F8C-A37E7B399B45.jpeg‎  

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    Re: Mini rebuild and rally build

    Just about finished cutting the rotten sills and door step out. A few little things need a repair before I can fit the new panels but we’re getting there.
    Attached Thumbnails Attached Thumbnails 43D05A1A-6CBE-4D9F-83FC-5F813DA6E731.jpeg‎  

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    Re: Mini rebuild and rally build

    Click image for larger version Name:	B05E3345-B29E-4215-B25E-F14492FD4DAB.jpeg Views:	251 Size:	138.1 KB ID:	86614

    It’s taken a while but it’s nearly ready to have the passenger side panels welded in. Still bits to tidy up as the passenger side was in an awful state, 3 plate patches welded on top of each other in some places... we’ll get there though.
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    Re: Mini rebuild and rally build

    i do love a mini gt two projects in the shed atm wich i will prob end up selling tho as just dont get the time between the other projects

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    Re: Mini rebuild and rally build

    Finally got the floor piece, inner & outer sill fitted today. Door step next then the heel board repair panel, rear arches and then the quarter panel.
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    Pit Crew Decade Plus User onecamohv's Avatar

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    Re: Mini rebuild and rally build

    jesus thats some commitment for someone that hasnt welded panels before! hats off, nice work - keep the updates coming

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    Re: Mini rebuild and rally build

    Cheers mate, it’s been a massive learning curve but I’m getting there. I enjoy the welding part quite a lot, it’s all the cutting, cleaning and shaping before hand I’m not a fan of haha.

    There’ll be plenty more updates as we go along.
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    Re: Mini rebuild and rally build

    Good job your doing there!
    What welder are you using and gas? Thinking of buying one myself and having a go on my escort.

  23. #18
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    Re: Mini rebuild and rally build

    Im using a Clarke 135TE Turbo that I've added a regulator to so it can run the big gas bottle. It does the job well in all fairness.. no doubt there are better welders out there, but for starting out, its ideal.


    Got the rear quarter on today. Lots of faffing about as it it just wouldn't sit properly but we got there in the end. Still plenty to tidy up and finish off before I can move onto the boot floor. The main issue I need to over come is that this has been de-seamed previously so trying to tie everything in is a bit of a challenge but I have a plan, which mean more fabricating but I'll get it done.

    I also tried the door on for the first time since putting the new floor section, sill and door step in. I was very pleased with how it fitted so hopefully the driver side will fit the same haha.
    Attached Thumbnails Attached Thumbnails mini 1.jpg‎  

    Last edited by Arwel; 06-04-2021 at 17:24.
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    Re: Mini rebuild and rally build

    Thought I would try the driver door since the passenger door fitted tidy. Well happy to report that the driver door also fits like a glove too.

    I've spent a couple of hours today just cleaning up the boot floor in preparation to repair it and cleaned up the rear panel around the window and the parcel shelf. I've got a little repair to do on the rear passenger wheel arch which will tie in with the boot repair. I've got the driver side rear wheel arch to repair and a few small repairs on the rear panel and then I'll be ready to spin it back over and protect and paint the underneath. Once that is done, it can come off the spit onto some stands and I can get cracking on the front end.
    Attached Thumbnails Attached Thumbnails mini driver door.jpg‎  

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    Re: Mini rebuild and rally build

    That looks as rusty as mine !!

    Don't think I could be convinced to try and repair it though. It'd be easier to get another shell
    9.85 @ 145mph 202mph standing mile

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  26. #21
    Spanner Monkey Arwel's Avatar

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    Re: Mini rebuild and rally build

    This was proper bad and if it wasn't for daft sentimental reasons then it definitely would have been a re shell haha
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    Re: Mini rebuild and rally build

    I've had mine around 30 years...I get it. But I do realise mine is just beyond sensible repair. Plus for a Mini project, I'd love to do a van
    9.85 @ 145mph 202mph standing mile

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  28. #23
    Spanner Monkey Arwel's Avatar

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    Re: Mini rebuild and rally build

    I've been really slow with updates but a lot has been going on. I'll get some pics soon and do a little catch up.
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    Re: Mini rebuild and rally build

    Hear i was thinking you ran out of Argon, keep it up as it will be a blast and we’ll done as it’s not as easy as people think

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    Re: Mini rebuild and rally build

    Looking forward to seeing how this one has progressed.

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    Re: Mini rebuild and rally build

    Thanks for the support guys. Im getting married in June and was hoping to have it ready for then but I was way too optimistic.
    Progress has been slow but I'll keep churning away.
    I'll have some updated photos this week now.
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    Re: Mini rebuild and rally build

    Finally have worked out how to upload photos again.

    Anyway, progress has been slow with getting married and I sort of bought another rally car...another old one of mine as it goes. Its a stage prepped Fiesta St so the poor mini has not had much attention.

    There is a plan in place for that to change so the mini has my attention as the Fiesta will be looked after by a friend who has started his own business. However the mini has been finished underneath, its not pretty but it'll be a rally car at heart so i wanted it to be practival rather than pretty.

    Next job is to sort the bulkhead and fabricate some new shock mounting plates for the front before it can have all new front panels and be closer to actually getting the body prepped for paint.



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