16v K1380 mini, I just couldn't resist ripping it apart again.

stevieturbo

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Use teflon lines and there will be no fuel smell. And TBH, I wouldnt use anything but teflon or OEM type rubber hose.
 

Ged

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I dont really have alot of time to look though the forums im usually desiging something or trying to find time to write a post when im on the PC, but this was well worth the read and a real credit to you, I cant wait to see it completed, Cheers for tagging mer @David.S.

Be good to chat about your experience with the PDM id have definatly had one in the GMC if they would bring out a 24V supported system that isnt a motec at 6k plus lol

I know your pain on the pedal boxs Iended up seperating everything and going for a high slung clutch and heel mounted brake. More work but it fit the feel of everything better with my high seat. You cant work it out till you sit in something sometimes.

I remember talking with Alan Roddy and Steven Gault years ago about high power minis and them spitting off teeth of the Crownwheel not sure if that will be an issue here.

Keep up the good work anyways, If its anything like my projects its sometimes as Frustrating as it is enjoyable but it will get there in the end.
 

cauld1

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Screenshot_20200801_083751.jpg


:monkey::joy:

Can't wait to see it done lad. Players Classic 2021 all being well!
 

jayme

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Cheers @Ged, been following the truck since you put thread up love how unusual it is for these shores. Looking forward to seeing it done.

There’s always the chance of the box killing itself, I’d suspect first would be the synchro hub. Crown wheel seems to be weird one, have saw people strip them on a fairly tame engine, and at the other end I’ve saw a casing split in a turbo car with the crown wheel unmarked. What seems to be the issue is the gearbox shaft starts to climb the pinion due to where the last bearing is positioned, away around it is fit an extra bearing at the speedo end for support.

As for the other kind words folks thanks, always nice to see it appreciated for the work gone into it.

@cauld1😂😂👏will still be done before that 205
 

jayme

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Had a pleasant surprise today in the form of the dash turning up, glad I went with the smaller display it just happens to be the perfect size for the mini.
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in the initial delivery of the first half of the pdm stuff I got one of the 12 button pads that ecumaster sell. Needed to mount it in the car where it could be reached, this led me to be creative and this is what I came up with.

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idea was a small mount that bolted up to the gear selector mount, cable could then be run down to p clips on the passenger side of the exhaust tunnel. Emailed it to someone doing some work for my brother and about a week later it turned up at the door. Some light finishing and a coat of paint and I fired it in to see if it works.

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Im proper happy with how it turned out, it’s also highlighted few minor changes I’d like to make to help with running the wires and the plug neatly.

Next up is a mount for the dash, plan is to make an adjustable version that mounts onto the steering bearing brackets. Will probably end up flocking them once completed.

thanks for looking
Jayme
 

jayme

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So last few weeks with the new year looming has me interested in the project again.

The mrs was good to me yet again this year , back at the end of October I found a DTA s60 on ig for sale due to a chap swapping over to a max ecu in a k20 mk1. An offer was made and a few days later it was accepted, came with new plugs pins, few sensors etc. Only catch was it was a “Christmas/ engagement” gift. So didn’t get my hands on it to the other day.

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Last week this was how the car sat

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I dropped the door of to replace pins in the hinges, while they where off I lifted a grinder and cut out the top door bars with the help of Jack. Long story was I never was happy with them, I was to go up and mock them up with the seat in but that never happened, an educated guess was made which was ok at the time until I then realised that when I was in the car with a seat practically in the floor that getting out was going to be a balls particularly when the door bar was practically running under your arm pit, and this would probably result in me not using the car. Anyway it’s done now, hopefully before I’m back in the office il have paint repairs done.

Next I had a look at the fuel lines again, I had them p clipped but it got messy. I bought some aluminium separators, tapped one side and ran a bolt through from the inside, in the end it pulled them much tighter into the side of the tunnel and left a more secure guide for the battery wire to the starter. Also left the bolt protruding so I can now bolt a heat shield over it all for some extra protection.
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I revisited the pedal box situation and basically back tracked to the original plan, however in typical style I’ve been modifying bits to reposition pedals and achieve the stroke. I think I will end up with my own pedal pads to help with packaging of 3 pedals in a tight space.

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also took this photo which I think shows a fairly good image of how the car will run ride height wise, thought it looked pretty tough for a mini

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The latest change in direction has come after some inspiration of friends on IG, when I set out to build this I wanted a stripped out bare bones car, what I’ve found even with it in the garage not driving is the up keep of the painted floors is going to be near an annual paint affair, and quite frankly I can’t be assed with it. Chap I met a few years ago built a mk1 styled mini on 13’s, always liked the way the overall package on the car and it has me thinking a nice interior is what my build needs to finish it

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And another car that has changed my mindset

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I can imagine not everyone will agree, but as I’ve said many times before I’m building a car for me to enjoy and I think an interior would make the car a bit more user friendly.

been waiting for a few bits from 3D printers but as with many things on the build if you don’t do it yourself you can’t control the time frame and quality, I should make the investment in a new computer and 3D printer but to me the money in that would finish this, hopefully my latest contact will be able to help with a few bits to get this going again.

cheers for looking
Jayme
 
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cauld1

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As you know id be fairly set against an interior in it with carpet etc, but something like Mark's one would be the ticket, and if it makes it usable it's a bonus.
 

big_pete

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My last one I ran with no interior and it made me use the car so much less and the upkeep of it is a PITA!
 

stevieturbo

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No interior at all would be a ballix, and surely the floor would be slippy as hell ?

It's not like there's a lot of trim in a Mini, or weight to worry about.
 

cauld1

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No interior at all would be a ballix, and surely the floor would be slippy as hell ?

It's not like there's a lot of trim in a Mini, or weight to worry about.
Griptape fixes that, but it is a balls to keep the whole thing clean and as @jayme says you'd need to be painting it every year to keep on top of marks etc.

My 205 is stripped and has body coloured floors (and will stay stripped once its back in one piece), worst thing ever was a burst can of coke going everywhere 😂
 

jayme

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No interior at all would be a ballix, and surely the floor would be slippy as hell ?

It's not like there's a lot of trim in a Mini, or weight to worry about.

Plan was always to run a floor plate with the grip tape ,I was never overly fussy on weight, target was always around 650kg as I thought it was a good target. If it comes in at 700kg I won’t be trying to find weight in it to cut, I suppose everything I’ve done I’ve kept it in mind so that it doesn’t add extra weight.

I just think the interior will leave a nicer finished car.
 

jayme

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Chipped away at this a bit more.

Decided it was time to knock a few jobs of the list, and of course it couldn't be straight forward and of the shelf......... because that just wouldn't do

Draw it up, send it to laser

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Mock it up

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Call in @PeteMoore...... Job done , If only the rest was this easy haha


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Pete also finished up my Steering column, only part left is to weld on the lug for a boss.

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Also knocked out the crank case breather, had to be an ITG to match


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And another of it looking sorry for itself, excuse the mess.

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Next up windscreen and plumb the brakes and clutch, its getting closer !!!!!

Cheers for looking

Jayme

Also gave my A7 a new year freshen up, have had this near 2 years now and basically I think im going to keep it. Not fussed on a thread for everyday cars or wheels and spacers projects so will just add a picture on the end as i quite like it haha, really is the perfect everyday car, oil change every few months and other than a wheel speed sensor its been a dream. Tyres are sore @250-300 a pop and the zf box service was also an arse bruiser (at least its done for piece of mind) but I guess any new car would be much the same.

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jayme

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New windscreen showed up, this is very much a milestone. Might be able to roll it out some evening and wash it. It’s been years and if anyone knew this car before the rebuild they will know how much pride I used to take in it. Looking forward to being able to get it detailed.

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fitted up the catch can to start making lines up, need to order some fittings to fine tune the routing. Also got the satin black out to make it a tad more discreet.

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plans for this week is get drive shafts fitted, new longer track rods on and the suspension all torqued up for final time. Will be contacting a few people this month to get car booked in for wiring which is an exciting prospect.

Jayme
 

big_pete

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Unreal buddy, I don’t think I’ve ever seen another mini built to such a standard!

my own gets some progress this month, I can only dream of it being even half as good as this!
 

jayme

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Well another 4 months on and ive got some motivation to make some more progress on this, hit another hurdle this time with fixing the exhaust where I lined up a lad to cut and weld it for me. Long story short he came eyed the job up, decided to cut the exhaust and studs down to make getting it in and out easier......... then never came back.

As you can imagine this was far from ideal so I thought feck it, il start myself. I knew from the off it wasn't going to be a perfect tig job but it held me up and it just needed done with the car leaving me in September for wiring.

Welder got re- commissioned

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2 lower parts mocked up to see if it was achievable and able to be assembled

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some cutting, and rework back and forth to tuck it right up and over to the drivers side

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back box fitted to check the rear is going to be ok, its leaning to the right atm due to the car being up like how it is

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and out for the final weld pass and to wrap for fuel line protection.

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with that on the cards I rolled it out for the first was in 6 years

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This is the end goal for ride height, rear might run a tad lower which should be fine as I specked the springs a bit overkill to save any sink carrying 2 people, full tank of fuel and a tool kit. Front will need some camber taken out of it.

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Next on the list happened by chance, I plan to use this next October for my wedding car, only catch was its not going to be me driving, more so the wife to be and one of her party. It took a while finally sell myself that idea but when the deal was done I realized the seats where never gona be ideal.
Fb messenger pinged one afternoon and Conor mentioned they had some old recaro's out of a capri, which by chance where the exact style I was after so they had to be grabbed, they need a full trim to be up to standard but with me going to be running an interior I feel they will fit the bill perfect.

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They are also a nicer seat to be in in terms of driving position and from a comfort point of view. I think at the end they will probably allow me to use the car more.

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Next up was to knock the steering column off the list, previously Id prepped the column and had Pete weld it all up for me, this time I had to get the shaft machined to take the snap off boss

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Some trick welding and it all bolted up perfect.

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From here the car is booked in for a full rewire, will be full tefzel loom, dtm plugs front to back covered in braid. I had planned doing some of the work myself but I just decided I cant be bothered half doing something for not a lot of saving in financial terms. After that all being well it would go straight to mapping once its starts and is checked for all the niggles (tbc with the relevant personnel). This however has put pressure on at my end to have full working brakes, fuel system and all that else would be required.

Last item on the Fuel system required was a FPR, as with most parts spec creep kicked in and an order has been placed for one of these. We will be able to control the pressure that makes the engine happy with room for growth down the line, fire on a sensor and we will be able to monitor it on the dash.

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Next up was the brakes, few hours of making a list and planning and the order was put in to make a start, yesterday a bag landed allowing me to start building up the pedal box ready to install.

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I thought id done well with my order thinking ahead of what I needed, Im a bit short so have to put a order in for another batch ( bank account takes another hit)

Hopefully things keep going well, just over a month to get it as close to finish as I can.

The pressure is definitely on!!!
 

jayme

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It’s been a very busy few months on this to wrap it up for the new year. I’m predicting some hassle with mot and insurance so the sooner it’s road worthy the quicker I can sort out the niggles ahead of regular use.

It now has a operating clutch and brakes, was a bit of thought getting the lines all clean and routed. It’s nothing fancy, but it’s simple and clean which I’m more than happy with.

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Had to call in some help from Conor and his dad, took a good chunk of a day but we got everything sorted after one minor leak and some patience with bleeding the bias box.

With that done I took into starting some of the trim work. Was in my head easier to start fresh than buy a pre cut kit, with the cage and amount of non standard work it would be butchered anyway. I taped the area with masking tape, drew around the edge before peeling it off and sticking to masking paper, trimmed it and test fit it before it finally got marked onto some carpet before being cut out and glued on

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At this stage I bolted in the display and the dash shell. I will wait until the car is wired before doing the main floor sections, I think I will end up drawing up some floor plates for under foot to make the carpet wear a bit better, off the shelf items wouldn’t lend themselves to any sort of regular use so a removable kick plate leaves you with a more robust heel area that is easy to remove and refresh periodically.

Next up was refit the pdm and ecu mount aswell as drill the holes to get the loom into the engine bay and inner wings .

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In the photo below you can see where the loom passes into the bay under the main crossmember, it’s all hidden out of site but easy got at. All the wiring is also hid behind the dash shell which can be removed in 5 minutes, in my opinion it leaves a very clean install.
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Next up was to button up the fuel pressure reg, ideally I’d have liked it in the engine bay to make it easy to adjust, however it was difficult to package it with the cooling hoses running on the side of the fuel lines, Next best was the boot beside the tank.

Nuke performance stuff is a bit of a masterpiece. This sat on my desk for a week or 2 before I fitted it.

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Also fitted one of these solid state pressure sensors to give the pressure display on the dash.

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The other one ended up on the oil feed to monitor oil pressure

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Other head ache was adapting the old oil temp sensor to take a modern fluid temp sensor, however that was one of the easier head aches to deal with. 30mins time, a hydraulic blank and a lidil pillar drill sorted that haha

All the engine bag parts fitted back up, only thing missing is a few hose clamps for the water pipes. You can just about see the injectors all mounted up.

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And that takes me up to running out of jobs to do, currently waiting my turn to get the loom done, on this occasion the delay actually suited me to get so much done. I swapped my slot with a group a Subaru taht needed some urgent for a guy, once it’s out the door the mini is up. All the time consuming and difficult stuff is done so it should really just be a run wire job with some laptop work at the end.

Rolled it out yesterday evening saying it was lovely evening

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Opportunity to pull the a7 up was to good to miss.

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This week I’m waiting on some parts in the post that I’ve been eager to get on the car for a while. Hopefully the next update should have an update on a loom.

Jayme
 

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FM155

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Alfa 155
Great to see this coming together, be good to see it out and about sometime when it's done.
 

jayme

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Cheers guys, its nice to be at the final corner (touch wood) Hopefully get it of to GNE to get look taken care of soon. In the mean time im working on the interior, if plans come into play I think it will make the car in terms of overall finish.
 
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