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1981 Mini City 1000

This section is for Mini projects and restorations and also the place to show off your pride and joy.

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ctwomey
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Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Mon Nov 23, 2020 12:03 pm

This was the drawing I threw together for the rollover jig clearance.
Screenshot 2020-11-23 at 12.02.05.png
Screenshot 2020-11-23 at 12.06.43.png



ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Nov 28, 2020 4:24 pm

Some progress on the roll over jig

Made the stands and happy with the outcome. Need to get some more steel to finish it off.
683E67CC-82A3-4FF2-AB40-EB152CDD73F2.jpeg
40EE6496-5974-4512-A35D-F1A11030A9FF.jpeg

colinf1
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Posts: 68
Joined: Mon Aug 24, 2020 10:27 am
Whats your location?: Dundalk
Region: Eastern
What Minis have you?: 1974 Aussie Leyland Mini 998 (Clubman front)
Current project is a 1983 Mini 1000
Contact:

Re: 1981 Mini City 1000

Post by colinf1 » Sat Nov 28, 2020 9:23 pm

That looks great, plenty strong, is that 50x50 box?

Are you gonna put some form of liner in your pivot point or have you used seamless tube?

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sun Nov 29, 2020 12:00 pm

The box section is (70 x70 x 3mm), the supports are (50 x 25 x 2.5mm) and the circular tubes are (88.9 x 5mm) and (76.1 x 5mm) used for the inside. Given the length I used for the outer tube is only 200mm long I was able to use an air grinder to grind away the weld seam so the inner rotates without any issues. There is also some 50 x 3mm angle and 3mm flat thrown in for other parts.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Thu Dec 10, 2020 12:07 pm

Not looking good on the Brexit front for people getting Mini parts in the future. Looks like we might be getting hammered with VAT and Duty unless some business in Ireland starts stocking the parts and imports them properly i.e. B2B.

Managed to get most of the panels I needed but still need a front wing, quarter panel and 2 x quarter floor repair sections.

colinf1
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Posts: 68
Joined: Mon Aug 24, 2020 10:27 am
Whats your location?: Dundalk
Region: Eastern
What Minis have you?: 1974 Aussie Leyland Mini 998 (Clubman front)
Current project is a 1983 Mini 1000
Contact:

Re: 1981 Mini City 1000

Post by colinf1 » Thu Dec 10, 2020 3:15 pm

Eeeeeekkkk...just pulled the trigger on my panel order, hopefully it gets dispatched and through customs before brexit day....

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The Marcos Graveyard
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Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Mon Dec 14, 2020 4:37 pm

All the old butter smugglers will be coming out of retirement........... :)
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A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Dec 19, 2020 7:43 pm

Very productive day today. Finally got the mini up on the rollover jig. I still have a few items to complete on the jig including adding castors to the stands, joining up the two ends with 60mm x 60mm box section to make it more stable and adding a mechanism to lock the rotation in any angle.
IMG_3858.jpeg
IMG_3859.jpeg
YouTube video of it in action is here https://youtu.be/7WWHgNd4xDE

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Dec 19, 2020 7:53 pm

Had a good look at the underneath of the shell. It's in very good condition.
IMG_3871.jpeg
IMG_3873.jpeg
IMG_3874.jpeg
The main damage is around the driver and passenger footwells. Looks like it was badly jacked in the past too.
IMG_3877.jpeg
IMG_3878.jpeg
The rear valence contains mainly surface rust but it's knocked out of shape.
IMG_3875.jpeg
IMG_3884.jpeg
Usual rot under the front wings isn't there.
IMG_3880.jpeg
IMG_3882.jpeg
Both rear subframe mounting points are solid
IMG_3885.jpeg
I think I have a solid enough shell to get cracking on with now.

colinf1
NON Member
Posts: 68
Joined: Mon Aug 24, 2020 10:27 am
Whats your location?: Dundalk
Region: Eastern
What Minis have you?: 1974 Aussie Leyland Mini 998 (Clubman front)
Current project is a 1983 Mini 1000
Contact:

Re: 1981 Mini City 1000

Post by colinf1 » Sat Dec 19, 2020 9:21 pm

Rotisserie is looking good! The amount of bits that are rattling inside the shell as you spin it! Anything good fall out??

Looks fairly solid all over, have you got your replacement panels for it or are you holding off til you have a good look at everything?

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Dec 19, 2020 10:04 pm

colinf1 wrote:
Sat Dec 19, 2020 9:21 pm
Rotisserie is looking good! The amount of bits that are rattling inside the shell as you spin it! Anything good fall out??

Looks fairly solid all over, have you got your replacement panels for it or are you holding off til you have a good look at everything?
Hi Colin

Yes, I found a 1980 one pence coin. The noise is just bits of rust that fell from the driver's side outer sill.

I have the following panels so far:
2 x front wings
1 x front panel
1 x rear valence
1 x battery box
2 x door skins
1 x boot skin
1 x RH side upper outer sill
1 x LH side rear quarter panel

Only outstanding items I need are the front floor repair quarters. They can wait for now.

Regards,
Conor

colinf1
NON Member
Posts: 68
Joined: Mon Aug 24, 2020 10:27 am
Whats your location?: Dundalk
Region: Eastern
What Minis have you?: 1974 Aussie Leyland Mini 998 (Clubman front)
Current project is a 1983 Mini 1000
Contact:

Re: 1981 Mini City 1000

Post by colinf1 » Sun Dec 20, 2020 5:57 pm

All that was in mine was an old 5p,not even a big on at that!

A few less panels than what I have at the moment, I picked up a good 2nd hand boot lid as mine was rusted through frame and skin along bottom.

Boot floor looks fairly solid, did you go genuine or pattern panels?

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sun Dec 20, 2020 8:16 pm

colinf1 wrote:
Sun Dec 20, 2020 5:57 pm
did you go genuine or pattern panels?
I went genuine so far for the simple reason this is the first car I am restoring and I didn't want to introduce extra challenges that sometimes the pattern panels could present. A seasoned restorer would know what is good and what isn't. However, I will go with m-machine floor quarters as I believe these are really good.

Started removing the battery box via the underneath. This way, at least when I plug weld the new one, the welds will be underneath and not in the boot area.
IMG_3939.jpg

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Tue Dec 22, 2020 6:54 pm

Finally created a locking mechanism for the roll over jig.

A lot safer now.
33607BA0-827F-4395-85CD-EAA5963E4A90.jpeg

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4701
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Wed Dec 23, 2020 11:41 pm

Nice simple solution.
Image

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

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Thu Dec 24, 2020 11:43 am

Added castors to the legs and a stabilising bar between the two ends and now it can be moved around the workshop with your little finger. Delighted with the outcome.

Total cost of materials was about €200 plus I learned to weld 2mm - 5mm thicknesses
0CFA5390-C736-4434-BD61-CCC1A823EE9F.jpeg

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4701
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Sun Dec 27, 2020 3:38 pm

Great work. :D
Image

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

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sun Dec 27, 2020 8:21 pm

Finally got the battery box spot welds removed. One or two holes to fill but marking out where the plug welds will be made.
1953DE65-784E-4D7C-866E-F71A18BAA636.jpeg
Switched the welder over to 0.6 wire and trying out some butt welding on some off cuts. Very different beast welding 0.8mm steel.
177DB4A4-52C7-4ED5-B57C-2794106E88A3.jpeg
Going to need lots of practice to tune in the correct welder settings. I tried 5mm holes for the plugs but they are too weak. 7mm seems to be rock solid.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Wed Dec 30, 2020 8:56 pm

Installed the battery box. Took ages as it was my first attempt at plug welding. Running the welder slightly hotter and getting good penetration. The boot is a difficult space to weld inside 😀
40A22EB5-3711-4472-BA8B-8D819283BAD2.jpeg
Started removing the old rear valence. Discovered a rusty area on the floor lip. Will cut it out and replace with some new metal. It’s going to be hidden under the valence lip, so a good place to test my butt welding.
15A1698B-4790-4F46-925C-8CDF6A0D7FEB.jpeg
4FC3ACFE-C65E-4ECB-A1D3-1EB3D5AC426C.jpeg
52204344-EFE3-4944-9952-5BE0EED8824F.jpeg
Stay safe everyone.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Thu Dec 31, 2020 12:43 pm

It’s a bit too cold in the garage today but managed to remove the passenger side end of the rear valence
E2AC3BE0-36D4-4C9B-85A0-92CCD8D95570.jpeg
Some additional small areas of the floor to be repaired in the corner.
Lots of hidden rust in these cars. It’s like an iceberg what you see is only 10%
6E622CA3-B56F-4262-B957-1CBA5D978A2B.jpeg

colinf1
NON Member
Posts: 68
Joined: Mon Aug 24, 2020 10:27 am
Whats your location?: Dundalk
Region: Eastern
What Minis have you?: 1974 Aussie Leyland Mini 998 (Clubman front)
Current project is a 1983 Mini 1000
Contact:

Re: 1981 Mini City 1000

Post by colinf1 » Thu Dec 31, 2020 10:57 pm

Are you going to reuse those closing panels or did new rear valance come with new ones?

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Fri Jan 01, 2021 10:13 am

I am going to reuse these ones. The closing panels are separate to the rear valence. There is only a tiny bit of surface rust on them that can be cleaned up. The area I need to replace is a small section of the floor that joins with the rear panel. It is perforated in a number of spots.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Fri Jan 01, 2021 7:29 pm

Removing seam sealer would make you cry 😢
7966322B-9507-4BD3-AF6F-43E2660D4F3B.jpeg

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Fri Jan 08, 2021 9:23 pm

Small amount of old collision damage that I will need to cut out of the inner wing at the bottom. Some brazing had been used to attach the outer wing to the inner one but that has been cleaned up now. Other side is spot welded correctly.

Those inner wings are a weird shape. Hard to determine the original shape.
7CDBBB04-0AE4-46BB-8C7A-809CC2575038.jpeg
Managed to order an 8x4 sheet of 1mm from an engineering shop in Portlaoise who will cut it up so it fits in my car.

ctwomey
NON Member
Posts: 75
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Jan 16, 2021 6:48 pm

Some metal will need to be cut from the inner panels and replaced with new metal. Too badly damaged to repair.
9C61841B-60B0-4E75-9912-8EA7C4A1BB5D.jpeg
D5DE829E-09A0-494A-8224-CE6CBB9C2294.jpeg
Surface rust on Outer sills were suspicious and a quick blast with the wire wheel revealed some rust holes. Time to remove them.
7D114DF8-3CDC-4D15-8AC2-4DC944E61181.jpeg
2987FDC7-B648-4D9C-A619-BAEF91C587E2.jpeg
Good news is that inside the sill cavity the metal is very good.

The other side door step is not in the same condition but I have a replacement panel for that.
950EB0FF-03E6-4AF5-ADA9-E6D66A745745.jpeg
Planning on getting the shell vapour blasted and epoxyed. Opening these cavities will be a great help to protect them long term

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