Mini rebuild and rally build

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  • Arwel
    Spanner Monkey
    • Jun 2009
    • 292

    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.
    Attached Files
    Last edited by Arwel; 10-01-2021, 17:02.
    sigpic Instagram: A86_Motorsport Facebook: A86Motorsport
  • Graham
    TURBOSPORT SPONSOR
    Turbosport Subscriber
    Turbosport Moderator
    Turbosport Administrator
    • Feb 2006
    • 25214

    #2
    Re: Mini rebuild and rally build

    cool, looks like you have your work cut out, nice to see something different too
    sigpic
    https://www.facebook.com/penguinmotorslimited?ref=hl

    Comment

    • Arwel
      Spanner Monkey
      • Jun 2009
      • 292

      #3
      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 Files
      sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

      Comment

      • alladdin
        World Champion
        Decade Plus User
        • May 2005
        • 9248

        #4
        Re: Mini rebuild and rally build

        good thing about minis is panel prices

        Comment

        • Arwel
          Spanner Monkey
          • Jun 2009
          • 292

          #5
          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
          sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

          Comment

          • mexicotait
            Racer
            Decade Plus User
            • Oct 2008
            • 2437

            #6
            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

            Comment

            • jimmy2006
              Pit Crew
              Decade Plus User
              • Feb 2009
              • 1986

              #7
              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

              Comment

              • Arwel
                Spanner Monkey
                • Jun 2009
                • 292

                #8
                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.
                sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

                Comment

                • jimmy2006
                  Pit Crew
                  Decade Plus User
                  • Feb 2009
                  • 1986

                  #9
                  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

                  Comment

                  • Arwel
                    Spanner Monkey
                    • Jun 2009
                    • 292

                    #10
                    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 Files
                    sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

                    Comment

                    • Arwel
                      Spanner Monkey
                      • Jun 2009
                      • 292

                      #11
                      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 Files
                      sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

                      Comment

                      • Arwel
                        Spanner Monkey
                        • Jun 2009
                        • 292

                        #12
                        Re: Mini rebuild and rally build

                        Click image for larger version

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                        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.
                        sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

                        Comment

                        • stumpy
                          Tyre Kicker
                          • Feb 2021
                          • 7

                          #13
                          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

                          Comment

                          • Arwel
                            Spanner Monkey
                            • Jun 2009
                            • 292

                            #14
                            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.
                            Attached Files
                            sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

                            Comment

                            • onecamohv
                              Pit Crew
                              Decade Plus User
                              • Jun 2012
                              • 1159

                              #15
                              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

                              Comment

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