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1981 Mini City 1000

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colinf1
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Current project is a 1983 Mini 1000
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Re: 1981 Mini City 1000

Post by colinf1 » Sat Jan 16, 2021 8:47 pm

Looks like your making good progress! Inner wings are looking good, have you much to do around door frame?

Have you a company in mind for blasting? The blaster I used said it was pretty hard to get the epoxy off for welding prep, but I see plenty of people using it so can't be that bad?



ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Sat Jan 16, 2021 10:05 pm

colinf1 wrote:
Sat Jan 16, 2021 8:47 pm
Looks like your making good progress! Inner wings are looking good, have you much to do around door frame?

Have you a company in mind for blasting? The blaster I used said it was pretty hard to get the epoxy off for welding prep, but I see plenty of people using it so can't be that bad?
Driver side door step has rusted through but I have the replacement panel for it.

Thinking of FMK for the vapour blasting and epoxy.

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woody
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Re: 1981 Mini City 1000

Post by woody » Sun Jan 17, 2021 10:09 am

Looks better jnside than any sills I ever opened. quite solid. nice.
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ctwomey
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Whats your location?: Ballybrittas, Co. Laois
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Re: 1981 Mini City 1000

Post by ctwomey » Sat Feb 06, 2021 4:36 pm

Busy few weeks with work and homeschooling like so many others, so haven't had as much time for the Mini. Managed to get out today and removed the driver side outer sill.
IMG_4238.jpeg
To get the piece of sill that is inside the rear closing panel you need to make this small cut in the corner to free up the weld.
IMG_4239.jpeg
Outer doorstep on the driver's side will need replacing as there are numerous holes in it.
IMG_4240.jpeg
Found the stamp on the outer inner sill indicating an '81
IMG_4242.jpeg
Also to keep the garage warm I purchased a small propane jet heater that is perfect for getting the cold out of the space.
IMG_4237.jpeg
Next is to finish up the areas where the outer sills join the floor and quarter panels, then on to replacing some steel on the inner wings that are damaged from where the front panel joins them.

colinf1
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Re: 1981 Mini City 1000

Post by colinf1 » Sat Feb 06, 2021 7:59 pm

General consensus is operator ID, then Week 07, 1981

Looks like your making good progress, and keeping warm...

My heater is a hat and a jacket lol 🤣

ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Sat Feb 06, 2021 9:15 pm

colinf1 wrote:
Sat Feb 06, 2021 7:59 pm
General consensus is operator ID, then Week 07, 1981
That makes sense. The car was registered in early April ‘81

ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Sat Feb 20, 2021 7:44 pm

Good day in the garage today working on the mini

Removed all the seam sealer off the bottom of the car. Just a small bit in the engine bay and then the interior to do
IMG_4268.jpeg
Cut out a repair patch for the inside front wing on the passenger side.
IMG_4269.jpeg
Sometimes the gap looks big but you get great penetration on the weld.
IMG_4272.jpeg
Tacked up ok but will have to come back to finish it off.
IMG_4273.jpeg

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Re: 1981 Mini City 1000

Post by Dalcash » Mon Mar 01, 2021 5:17 pm

Fantastic thread on restoring a classic. I'll being doing my own restoration shortly and a lot of very valuable info in this. Thank you very much for taking the time to document the build.

Quick one regarding the crankshaft endfloat. You said you have it .003" which is what the Haynes manual would suggest. Haynes says .002" to .003" endfloat. However, Cole at Classic Mini Diy had an issue with the crank endfloat and he says that the Haynes manual is wrong. He had .002" on his engine which is also in the Haynes spec but it caused issues, as when the engine was at temperature and he pressed the clutch the engine was binding and stalling. Turns out he had too low a clearance on the crank endfloat. He said that engine builders usually go with .005" - .007" crankshaft endfloat. When he disassembled the engine to fix the issue the endfloat was .0035" but still too tight. He increased the endfloat to .006" and this fixed the issue.

What are your thoughts on this. I'll need to do it myself soon and I have more questions then answers as to what the crank endfloat should be.

Here's a link to the video to better understand the issues he had
https://www.youtube.com/watch?v=mx8HksuAw48

Thanks in advance. Best of luck with the build.

ctwomey
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Posts: 112
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1978 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a 1982 MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Tue Mar 02, 2021 9:39 pm

Dalcash wrote:
Mon Mar 01, 2021 5:17 pm
Fantastic thread on restoring a classic. I'll being doing my own restoration shortly and a lot of very valuable info in this. Thank you very much for taking the time to document the build.

Quick one regarding the crankshaft endfloat. You said you have it .003" which is what the Haynes manual would suggest. Haynes says .002" to .003" endfloat. However, Cole at Classic Mini Diy had an issue with the crank endfloat and he says that the Haynes manual is wrong. He had .002" on his engine which is also in the Haynes spec but it caused issues, as when the engine was at temperature and he pressed the clutch the engine was binding and stalling. Turns out he had too low a clearance on the crank endfloat. He said that engine builders usually go with .005" - .007" crankshaft endfloat. When he disassembled the engine to fix the issue the endfloat was .0035" but still too tight. He increased the endfloat to .006" and this fixed the issue.

What are your thoughts on this. I'll need to do it myself soon and I have more questions then answers as to what the crank endfloat should be.

Here's a link to the video to better understand the issues he had
https://www.youtube.com/watch?v=mx8HksuAw48

Thanks in advance. Best of luck with the build.
Thanks for the feedback Dalcash. I didn't do videos because I wanted to enjoy my time in the garage away from all technology. At least with my phone in my pocket, I can take a few pictures and post them here along with some descriptions and build up the thread.

Yes, I saw Cole's video after I finished building the engine. I suppose I won't fully know until it is running in the car and I test the clutch. I did actuate the clutch using a metal bar when I had it running out of the car and it was ok, but the real test is when I put it back in the car. I wonder if it affects big bore engines more than small bore.

Hopefully, I can get back to the bodywork on the Mini over the next week or so.

ctwomey
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Whats your location?: Ballybrittas, Co. Laois
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Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Mar 20, 2021 10:33 pm

Made a complete mess of the previous patch panel.

Decided to cut it out and start again.
1BB9A89C-76FF-47C2-88DD-DBD3F30676A2.jpeg
I spent a bit of time practicing on some off cuts and I think I have tuned the welder settings for butt welding 20gauge.
F855F50F-4961-43E0-B32F-2279D102DC8D.jpeg
Took my time with the welding
B4584B59-04CB-4052-8825-FAA1EB63AFD0.jpeg
FE26251B-AF90-4D01-998C-2AEF6E3A304B.jpeg
Really happy with the final results. Probably took on the hardest form of welding as both sides of the butt weld are visible.
2083DFC3-3082-45A2-AEFD-0288DA1329FB.jpeg

colinf1
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Re: 1981 Mini City 1000

Post by colinf1 » Sun Mar 21, 2021 2:34 pm

How does it look on the opposite side? Looks like you got good penetration and no pin holes or blowing through...

Should have the welding nearly finished now :P

ctwomey
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What Minis have you?: I owned a 1978 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a 1982 MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sun Mar 21, 2021 6:27 pm

colinf1 wrote:
Sun Mar 21, 2021 2:34 pm
How does it look on the opposite side? Looks like you got good penetration and no pin holes or blowing through...
Hi,

These images will show you the penetration for each side.

Frontside
26BAFDFB-E54F-4AEE-AEAC-52D263E25702.jpeg
Backside
4A2A2531-B3C2-455A-A421-A65E5732FFB9.jpeg

ctwomey
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Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sun Mar 21, 2021 6:30 pm

This is the inside of the inner wing finished off
F9782598-12A9-41C8-B021-D1BCAA548429.jpeg
Now to repair the other side
C9AA022D-B1CC-47C5-B9A6-1589C7B21D2B.jpeg

colinf1
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Re: 1981 Mini City 1000

Post by colinf1 » Sun Mar 21, 2021 7:58 pm

That looks really good, can't see the join at all...

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woody
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Re: 1981 Mini City 1000

Post by woody » Sun Mar 21, 2021 10:09 pm

Great work ,pratice makes perfect
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ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Sun Mar 28, 2021 8:10 pm

Fixed the mess on the other side
IMG_4445.jpeg
If you want decent penetration at low temperatures then you need to have a gap of 0.9-1.0 mm
IMG_4446.jpeg
Tacted up
IMG_4447.jpeg
Ground down the previous tacts so I can add the next tact beside it
IMG_4450.jpeg
Grinding down welds is tricky but an outside bend is the easiest. Inside bends or inside 90-degree bends is much harded. Always worth welding from the outside of any curve. The penetrated weld is much smaller.
IMG_4454.jpeg
Put some etch primer on until the shell gets vapour blasted.
IMG_4455.jpeg

colinf1
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Current project is a 1983 Mini 1000
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Re: 1981 Mini City 1000

Post by colinf1 » Sun Mar 28, 2021 9:37 pm

That's looking very neat and tidy indeed! It's amazing how a coat of primer transforms the look of it and makes you feel like it was worth all the hassle!

Keep up the good work...

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The Marcos Graveyard
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Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Tue Mar 30, 2021 12:39 pm

Nice job 8)
Image

A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Sun Apr 04, 2021 5:03 pm

The more you work on these minis the more you realise how bad the manufacturing process was. Amazing how any of these survive.

Bare metal with no protection. Seam sealer plastered everywhere. Big blob under rear slinging brackets.
47FD5572-6657-4644-94C0-24F0FB1EA136.jpeg
CA009426-3044-405B-ACB2-8B04F77A532A.jpeg
9B8974ED-2E29-4AB0-9773-17482F6CEDE0.jpeg
B1B4A65E-7BD9-4BE3-AF2A-EF9BFA91EBCA.jpeg

ctwomey
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Re: 1981 Mini City 1000

Post by ctwomey » Mon Apr 05, 2021 6:12 pm

Stripped the outer skin off the boot. Have a heritage replacement but will need to cut out some rust and replace some metal on the inner one before it can be considered usable.
CE2B0515-D732-4701-9E6C-5187937FE4E2.jpeg
6256D22D-C903-4F4C-B830-41827A074DA0.jpeg
B8B42664-7B56-4F41-BEF7-752C5CBD233C.jpeg

Johnd101
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Re: 1981 Mini City 1000

Post by Johnd101 » Mon Apr 05, 2021 8:27 pm

Great work really gives me great inspiration for my own one

colinf1
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Re: 1981 Mini City 1000

Post by colinf1 » Mon Apr 05, 2021 11:21 pm

Was it hard getting the boot skin off? Did you grind it or unfold it?

ctwomey
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Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Tue Apr 06, 2021 10:00 am

colinf1 wrote:
Mon Apr 05, 2021 11:21 pm
Was it hard getting the boot skin off? Did you grind it or unfold it?
Just use a 60 or 80 grit flap disk on the edge until you see a hairline crack in the steel, that will indicate that you have ground down through the bend of the fold of steel.

There are four spot welds you will need to remove. Two under the hinges between the two holes and then two more in the lower part of the reg plate area. I just ground them down from the outer skin side and then the internal frame was undamaged.

ctwomey
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Whats your location?: Ballybrittas, Co. Laois
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What Minis have you?: I owned a 1978 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a 1982 MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Wed Apr 07, 2021 9:09 pm

Got the outer skins off both doors.

Just a strip at the bottom that needs replacing on both.
2A603A64-B298-4C74-98F5-132BB045B3AE.jpeg
Passenger side is a little worse for wear but very repairable.

Lots of welding to do but just think I will be a dab hand at it when this is all done (note: keep saying that to yourself)
55531FFD-2B35-41F3-8EB8-78639882A39E.jpeg

colinf1
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Current project is a 1983 Mini 1000
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Re: 1981 Mini City 1000

Post by colinf1 » Wed Apr 07, 2021 9:18 pm

Great work, planning on attempting mine this weekend, both need the bottom repair panels.

Same process as the bootskin? There's a few spot welds to drill out too?

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