project Boris the '59 Minor.

[Joey spud]

Six months have flashed by and not a lot has happened to the Minor. I blame the house move and the ongoing internal alterations but tbh it's more lack of motivation in the winter months.

Anyhow I need to get the car usable as a fun village runabout.

I scored another cheap carb at an auto jumble a while back but my poor running/holding back at speed still remains. It has a wax stat jet so I need to carry out the penny coin delete on it to see if that helps,I am certain it's running weak and wonder if I move the metering needle up into piston slightly if that would richen it up more although the previous owner was using the inch and a quarter 1098cc carb on this engine and said it was ok.

While it's been parked outside the screen rubber has shown its age with rain water pooling on the front floors. The car came with a full set of window seals and even a spare screen so without much thought I dived in and cut the inner lip from the seal and popped the screen out.

 

The screen surround is excellent condition despite letting so much water through.

The screen I removed was laminated and had started to go cloudy in the bottom corners and it also had a large chip on the nearside so I dug out the spare screen which was in much better condition but was a toughened glass item.

I procrastinated for a while over what screen to use. In the end the thought of a facefull of glass if the screen got struck didn't appeal so I went with putting the tired laminated one back in.

Stupidly I had assumed the new screen seal was the right one but alas it was for a 1966 onwards car which uses the chromed plastic insert to lock the seal tight to the body/glass whereas my old one used two lovely bits of chromed metal and they couldn't be used on the later seal.

I could of ordered the earlier seal but i decided it didn't really matter though deep down I was annoyed with myself for not checking sooner.

I've done a few screens over years and have used the string in the inner lip and lashings of soapy water method to successfully refit the glass but this one was a right shit. It was as if the new seal was too big to pull in around the top corners and eventually I made a stupid mistake of thumping on the edge of the screen and cracking the upper corner.

So I ended up using the toughened screen after all.

The screen is back in now but the corners fit a bit pants but I think with the plastic locking trim fitted the seal should sit against the body ok. I have also got a tube of the correct non setting screen sealant to pump in between the two. 

I recall when I was a first year apprentice at a Vauxhall dealer the early MK2 Cavaliers suffered with water ingress from the front screen seal and it was the apprentice/grunts task to pump mastic between the seal and the body and the seal and the glass which was easy enough to do but the cleaning up of the excess mastic afterwards took forever. I think we used duck oil to get it off.

I have tried fitting the plastic trim which in my younger days I could do with a blunt screwdriver but not this time so I have had to invest and am waiting for the proper tool to arrive.

In hindsight I think I could of reused the original seal (if I hadn't of cut it off) and got away with removing the dried out mastic and injecting some fresh.

Rainwater has also been getting via the wiper spindles because the gaskets are knackered you can buy new ones for about £6 but I'm sure pushing the wheel boxes inwards slightly and applying some non setting mastic instead will suffice.

The awkward gap that is normally covered by the front bumper really needs a panel of some kind to tidy the front of the car. I've often thought someone could make such a thing and then sell them to other weirdos who want to run their Minors bumperless.

My wishes were answered when a guy started selling just such an item on eBay so to save the effort of trying to make something I brought a pair of his creations.

The nearside one has just needed a bit of bending to make it fit ok but the offside is going to need a dose of cutting and tweaking.

But once they're painted up I think they will look good enough for my desired level of scruffiness.

[2flags]

This is looking good. Well done on your house move. Glad it all went fairly smoothly. You will be chuffed to bits to get this running properly. As to the fueling problem, is the throttle spindle worn? That could let air in and weaken the mixture. 

[Matty]

Ive put an inch and 3 quater on the 1310 I've built. I did run it briefly on my old inch and half and it was acceptable but noticeably hesitant. I can't imagine that Searle built 1275 would be much differant to mine so that's the route I'd go down. 

Vizzards graphs show a HS4 as being at the top end of what it can flow at about 65hp (as a single obvs). HS6 are cheap and plentiful as everyone wants HIFs.

I swapped the waxstat jet for a fixed jet. Burlen do a conversion kit where you don't need to alter the choke mechanism and it isn't dear.

[N Dentressangle]

9 hours ago, Matty said:

Ive put an inch and 3 quater on the 1310 I've built. I did run it briefly on my old inch and half and it was acceptable but noticeably hesitant. I can't imagine that Searle built 1275 would be much differant to mine so that's the route I'd go down. 

Vizzards graphs show a HS4 as being at the top end of what it can flow at about 65hp (as a single obvs). HS6 are cheap and plentiful as everyone wants HIFs.

I swapped the waxstat jet for a fixed jet. Burlen do a conversion kit where you don't need to alter the choke mechanism and it isn't dear.

That's interesting.

I've got a 1275 to go in my Mini build, but need a carb for it and was going to do the obvious HIF44 thing. I do have a brand new HS6 kicking around - you reckon it would work?

[Matty]

8 minutes ago, N Dentressangle said:

That's interesting.

I've got a 1275 to go in my Mini build, but need a carb for it and was going to do the obvious HIF44 thing. I do have a brand new HS6 kicking around - you reckon it would work?

No expert here (you need @Tommyboy12 for that) but going off how it's going so far I'd say yes. HS6 is inch and 3 quarter like a HIF44 but miles cheaper. Obvs mines a bit bigger on the bores and has that mild cam in it. Since Tom's been steering me I actually did some research (unbelievable Jeff 😄) and the likes of AC Dodd and Calver do list needle designations for the bigger carb for a range of 1275 applications.

On Tom's advice I went BDK as its a bit richer but the general consensus seems to be BDL. I'm a bit fucked round here now for rolling road access but if provision is better down yours then I'd defo sling the HS6 on, get it running good enough and get it set up dynamically.

[Matty]

As an aside I met a 1380 a series with twin HS6s in a historic rally Mini at weekend. Built by minisport and making 120hp on the dyno. Asked him what it idles at. His reply was "it doesnt". 🤣

[Tommyboy12]

HS6 is definitely fine on a 1275. Should be good for about 100hp. BDL is a great needle to start with as said. Porting and polishing the carb might net you a couple of hp if you're up to it. Porting the inlet throat and bottom of the slide is good for airflow as is wedging the butterfly and halving the butterfly shaft. Mods I do all the time as it's just time for free power.

[Joey spud]

My inlet/exhaust manifold is (as far as I was told) from an 1300 Ital but the intake diameter is way bigger than an inch and a half. Are Ital and mini one piece manifolds actually the same ?

It starts first flick of the key with a HS4 fitted but falters and holds back on the road when trying to go past half throttle. Maybe a HS6 would match the manifold better ?

 

[Joey spud]

The screen trim fitting tool arrived this morning and the diamond shaped spreaders were either too small or too large but it did help to get the trim started enough for me to revert to the blunt rounded screwdriver technique to lift the rubber and "walk' the trim in.

I have applied mastic behind the seal at all 4 corners and then right on cue it started chucking down so I'll soon find out if I've stopped the water ingress.

[Matty]

1 hour ago, Joey spud said:

My inlet/exhaust manifold is (as far as I was told) from an 1300 Ital but the intake diameter is way bigger than an inch and a half. Are Ital and mini one piece manifolds actually the same ?

It starts first flick of the key with a HS4 fitted but falters and holds back on the road when trying to go past half throttle. Maybe a HS6 would match the manifold better ?

 

Don't know who made your inlet manifold but I have a minisport one and it is for both inch and half and inch and 3/4 su carbs. Just add 2 extra studs for the larger carb as 4 stud pattern. Couldn't get a throttle abutment plate for the HS6 so I made a plate and TIGged the return spring bracket and throttle cable bracket to it. I would imagine your manifold to be suitable for both if over inch and a half bore.

This is the genuine SU fixed jet conversion kit from Burlen. Moss do one but it involves pulling the choke linkagelinkages and changing the arm. The Burlen one you just fit the jet which has a little bracket on the side and refit the arm and clip of the choke linkage. 5 minute job. Not expensive either.

Ring Burlen though and they will talk you through it to make sure you get the right part number based on whether the carb you have is left or right handed.

[bunglebus]

I was wondering just yesterday how the Morris was getting on. I'd like to get one myself once I have suitable storage/repair facilities built

[Joey spud]

On 30/05/2024 at 18:30, bunglebus said:

I'd like to get one myself once I have suitable storage/repair facilities built

I don't think you can go wrong with a Minor. Every part is available new or second hand and upgrades to the engine,brakes, suspension etc is a well trodden path.

There's always loads of them out there to choose from and despite their dowdy image they drive really rather well.

[Joey spud]

I've been fighting Mr Lucas and his loom connections.

Since I discarded the control box and added a larger fuse box a couple of years back I knew at some point I would need to go through the wiring and get everything working again.

I had just one front side light working (now moved into the head lamps) and nothing else.

First off the simple light switch needed its contacts cleaning so I now had power to the dip/main switch.

That was removed,tested for continuity and bathed in contact cleaner and WD40.

With it plugged in under the bonnet I still had nothing at the head lamps.

But after careful cleaning of these horrible bullet connector block/terminal things at the dip switch and the head lamps I finally had light although the n/s was dim which I assumed was a bad earth that I chased and cleaned only to find some throbber had fitted a 24v bulb.

I didn't even know I possessed anything 24 volt.

For the dash illumination I bought some 'soft white' led bulbs that fitted fine although someone before me had fitted the oil light bulb holder into a Illumination socket so that explains why my oil light never worked. 

My wipers were really slow and weak so I was going to strip and clean the linkage but while I was at the dash I wanted to fit the wiper switch better as it had a lot of threads showing. To remove the switches knob there is a little spring loaded pin that is pushed in to allow the knob to slip off but my one was jammed on and fell apart when I tried to force it off so instead I replaced it with a toggle switch which instantly cured the sluggish wiper action (high resistance across the switch ?).

The later addition electric screen washer pump is operated by a scruffy on/off toggle switch which I swapped over to a nicer toggle flick on/off switch instead.

Much better. At some point the car has been repainted from a light grey to the darker Clarendon grey but whoever did the interior added a few heavy runs and blemishes to the fascia panel. I was going to rub it back and respray it but tbh it's part of the cars character/history so I'll leave that for the next owner.

The indicators are driving me nuts, originally Boris had semafore signals but over years got converted using a Mini stalk.

For some reason I have a fear/mental block understanding indicator wiring and although this mess mostly worked the tell tale would only flash for the n/s lamp. I know Boris doesn't need a MOT but I want it correct where possible.

So i bought an electronic flasher unit that also beeps so if I couldn't get the tell tale working I could delete it and fall back on the beeping as an audible warning instead.

Anyway after much coffee and trial and error I have got the indicators and the stalks horn push spliced into the Minors loom and working 100% I just need to tidy the nest of wiring up.

For front flashers I am using these little glass lamps that I guess were designed to be side lights and so you can't fit a large 21w bulb to them so for now I've fitted a smaller 10w bulb which seems bright enough. I'm sure there must be a small higher wattage led bulb available.

Despite my best efforts with caulking my old chrome number plate lamp fills with rain water that then drips into the boot so I have copped out and bought a cheap black plastic replacement for which I can only apologise.

 

[IronStar]

Had a cracking afternoon reading through the entire thread. I love the amount of work and dedication that went into reviving this car, despite everything that was going on in your life and with the world in general. 
i hope you find time and willpower to finish the car soon(ish). 
Good luck with rest of the Lucas smoke generators!

[Joey spud]

Thank you Mr IronStar, much appreciated.

I think I have conquered the wiring in as much as I need to purchase a handful of the black Lucas connector plugs rather than rely on 65 yr old examples.

 

[2flags]

It's lovely to see you battling through all the problems. Each of these little problems solved and sorted make the car a better thing to drive. It is looking great.

[Joey spud]

Ok moving on. The indicator wiring has now been shortened and rerouted out of sight inside the dash and the Lucas connections mostly got cut out and the wires soldered together instead it'll be a pain if the switch dies but never mind. The red tell tale light has been moved from the column onto the dash I think I will change it to green one at some point.

The number plate lamp swapped straight over using the existing holes which was nice and I poured the contents of the kettle over it and the boot stayed dry. I actually like the black over the chrome too.

After the faff changing the front screen seal I bailed out on the rear one as they are notoriously horrible to attempt but I cleaned the glass and added a sticker.

The seat back needs help.

The steering column had a lot of movement in it as its felt bushes were dry and worn but I have a spare column with nearly new bushes fitted so it made sense to swap them over.

There's a bracket on the column and I don't know what it's for but it gets in the way of the indicator stalk so I cut it off.

 

I had a little bit of wrinkle paint left over from doing a Honda cam cover a couple of years back so layered it on as thick as I could. It really needed a third coat but it's ok.

Back on the car it looks ok and I've been able to move the stalk right up to the underside of the wheel.

There's no cowling for the stalk but I think it looks quite racy being exposed.

[danthecapriman]

I’ve missed sooo much of this thread somehow! Great work 👍

[2flags]

Tell me, have you got the trafficators working as well as the indicators? 

[Joey spud]

On 09/06/2024 at 22:44, 2flags said:

Tell me, have you got the trafficators working as well as the indicators? 

No the trafficators are long gone. The arms are there but they're bonded into the quarter panel.

[tooSavvy]

My MM1000 van, yellow Ex P.O. , had a 'filter bypass' warning light (amber IIRC) and I snipped the wiring around so the indicator telltale (end of stalk) became this light.

I had fitted a smaller/thick rim wheel - so could not see the stalk end flashing.

Did for [19yo me] 👍

🚙💨

[Joey spud]

When I refitted the front torsion bars I got the nearside one spline too high,so four fingers between tyre and arch on this side and three on the offside.

So I found time earlier to move the lower arm up one spline to lower the ride height.

While I was there I renewed the recently replaced but now split rack gaiter and lower pivot grease seals again.

Back on the deck and one spline seems spot on although you can do some fine tuning at the other end of the torsion bar if needs be. I was a bit worried because the nearside rear suspension was also higher than the offside rear and I thought maybe I had welded the spring mounts in the wrong place or something but now the front is corrected the rear has sorted itself out too.

I popped a pair of the 14 inch wheels on and the car sits nice and level although the front tyre does stick out from under the arch slightly. These tyres are 185/70's so I am going to try a pair of 175/70's on the front to see if it helps.

[tooSavvy]

Further...... The 'top hat' rubber bushes, for the torsion bars/bottom mount, had been 'service upgraded' [by the P.O. workshops] into a steel/metalastik rubber bush... A very tough setup for the rigours of suspension/steering inputs... The bush [.. obvs 🙄] had been hacksawed to length, to fit the bottom mount.

'People Who Know'.... Eh? 😎

🚙💨

[Joey spud]

Yeah mounting the top and bottom suspension pivots on wobbly rubber wasn't a great idea.

Mine is all now polybushed in purple,green and boring black nylon.

[Matty]

could just be me but I'd almost be tempted to leave off painting it. Wheels look class.

[tooSavvy]

Dismantling the front torsion bars [to drop the front] I found the banded 5.5x13 + 175/13" tyres had a bit of fretting on the wing edge.... Rears, banded 6x14 + 185/14" were ok.

It looked a bit 'radikkal', on the Nose down Stance profile... I did adjust the lights to suit MOT heights 👍

🚙💨

[Joey spud]

2 hours ago, Matty said:

could just be me but I'd almost be tempted to leave off painting it. Wheels look class.

Yeah I am just going to grey primer the yellow bits then dust over the top with a black guide coat for now.

[Stinkwheel]

Ok, i read this whole thread yesterday and now i want a Morris Minor, dammit, yet also cool - Goes off to hit e-bay

[tooSavvy]

4 minutes ago, Stinkwheel said:

Ok, i read this whole thread yesterday and now i want a Morris Minor, dammit, yet also cool - Goes off to hit e-bay

 

🚙💨

[Stinkwheel]

Tempting, very tempting