Tommy's A-series Misery - Mini Welding!

[Tommyboy12]

Ive decided to put the Cavalier up for sale. I have achieved what I set out to do with it which is to get it back on the road in a condition that is acceptable to drive it in. Ive taken it to a few places and now I think its time to move it on so I can no doubt buy another car to fill the gap on my driveway 😅

Also shameless plug for the bike which is also still for sale. Ive dropped the price on it.

 

[BorniteIdentity]

Aye, the Monty looks a million times better now.  About 10 years ago I watched a bloke rollering and brushing a MK3 Transit van at the side of the road.  I was absolutely certain it was going to look a complete bastard at the end but, you know what, it looked really smart!  I'm not sure I'd want to do it on a regular car, but on something that's supposed to be useful/purposeful you can get a really great finish for £notalot.  I'd love to try it on something one day!

GLWS on the Cav.  

[Tommyboy12]

Busy day on the MGF today. First started off with a cambelt and water pump. It went swimmingly well which is exactly the opposite of what I expected.

It definitely needed changing. This thing was a literal ticking bomb. Cut and feathered although not all that cracked.

I forgot to buy an alternator belt but it definitely needs it.

Next up was a modification to satisfy my boy racer side. Fitting a 52mm throttle body. Fairly common modification on the K series. Doesn't do much for the power but quickens up the throttle response. I also fitted a hot air intake because I'm a child.

Before.

After

I drained the engine and gearbox oil next. Neither of which has been changed for a long time. Unfortunately I bought the wrong oil filter cause I'm a muppet so I'll fill the engine back up later but refilling this particular gearbox is a bit of a pain because you refill it from the dipstick hole with a bit of hose. Its a slow process as there's no vent so need to wait for the air to burp out.

Lastly I tackled my nemesis. Rust. There isn't much of it but the corner of the sill needs rebuilding. I knew it needed some welding but there's a bit more work than I was anticipating.

Still needs a fair bit of work. I've got to weld those holes up. It needs new shock absorber bushes as they're gone on the driver's side. Brakes and pads all round.  I need to weld on a new exhaust hanger. I'll probably change the fuel filter too as the idle is a bit rough and it's not likely to have been changed in a long time seeing as the filter is still stamped Rover! Then I have to sort the horn and wipers which don't work. Then it should be MOT worthy!

[Tommyboy12]

Bye Bye Cavalier

 

Hello next project 😅

 

 

[High Jetter]

1 hour ago, Tommyboy12 said:

Hello next project 😅

God that looks grim! Well bought

[Tommyboy12]

What's the only logical thing to do when you buy an unknown project that's been parked under a tree? Well if you're me it's to buy an unknown project that's been parked in an industrial estate...

It's a genuine 49k mileage 1979 Mini auto. With an engine that is definitely never going to run again. It needs welding but really not that much. A few weekends worth of welding in each corner. Everything above the sills is remarkably good considering it's age. However, it's 3579 shades of russet brown (the best BL colour ever!). It also comes with brown seats. Brown door cards. And I've sourced a brown carpet.

Did I mention brown?

[Tommyboy12]

I also did some more work on the MGF this week. Three projects seems a good idea...

I fitted the alternator belt and the correct oil filter.

I started fitting a new exhaust

And I swept up the bits that had fallen off...

I also fixed the wiper motor! The list grows shorter for the MOT. Handy when I need to fix other cars...

[Dick Longbridge]

19 minutes ago, Tommyboy12 said:

What's the only logical thing to do when you buy an unknown project that's been parked under a tree? Well if you're me it's to buy an unknown project that's been parked in an industrial estate...

It's a genuine 49k mileage 1979 Mini auto. With an engine that is definitely never going to run again. It needs welding but really not that much. A few weekends worth of welding in each corner. Everything above the sills is remarkably good considering it's age. However, it's 3579 shades of russet brown (the best BL colour ever!). It also comes with brown seats. Brown door cards. And I've sourced a brown carpet.

Did I mention brown?

What a find! Made me think though...

 

[sharley17194]

Its almost like you enjoy rust in your eyes and weld splatter down your arm!

[Tommyboy12]

I've had a wet weekend of working on cars in the rain. First off I had a breakdown... Alternator shat it's guts. I've never smelt an alternator like it. No bearing failure but definitely on the verge of being on fire.

Thankfully I was kindly lent a noble steed by @sharley17194 to get me home as it took the RAC 18 hours to recover my Megane 73 miles...

I'm going to chuck the alternator replacement at my local garage. I don't have time or the inclination to do it.

Once home I had to change the oil pump on my white Mini. Oil pressure was taking to long to build because the oil was draining back into the sump once sitting. Basically a bad sealing oil pump. I've caught it early thanks to a pressure gauge being fitted so I'm not worried about damage to the bearings. Not impossible to change with the engine in situ but a bit of a pain. Still not back together but nearly there.

I also assessed the brown Mini (named Poonelope by my better half). It's ok. As I expected and not actually too bad. It needs a wing, front panel, both front floors, door steps, rear floor repairs, companion bin, and boot corner repairs. Some absolute neanderthal also cut out the rear seat bench which is a more painful panel to replace. Might seem a long list but nothing I haven't done before and fairly simple repairs.

 

[Tommyboy12]

Did some MGF stuff this weekend.

Wipers now work after I finished stripping and cleaning the rack then regreased and reassembled.

I did change the clock spring to get the horn to work and it worked for all of ten minutes until I turned the wheel and heard a twang. Now it doesn't work again...

I also changed the holed half leathers for some full leathers. They are a slightly different colour but a nice addition I think.

All I have left now (apart from the horn again) is the welding and exhaust being refit. I'm nearly there with it.

[rob88h]

On 7/13/2023 at 5:00 PM, Tommyboy12 said:

The reg on that Mini is apt…

EDIT: I’m also very much in love. The world needs more shitty Minis. 

[Tommyboy12]

2 hours ago, rob88h said:

The reg on that Mini is apt…

EDIT: I’m also very much in love. The world needs more shitty Minis. 

The plan is to keep it rough. I've set myself a challenge of a £1500 roadworthy Mini. About as cheap as you can do it nowadays unless you get really lucky.

[Matty]

On 7/17/2023 at 10:51 AM, Tommyboy12 said:

RAC 18 hours 

Nuff said

[Tommyboy12]

Tonight I finally finished the oil pump job by putting a new clutch seal on the Mini and getting it back together. Oil pressure shot up immediately and ran at a nice high 80psi. About right for a tight cold A series. Now I can move it to weld the MG which I may start tomorrow evening if the weather holds.

 

[Tommyboy12]

Got some work done on the MG. Welded some holes up with the help of CAD.

Sill end first

Then the sill itself

Then fold over to make the roll in the end and seam seal

Then a coat of the finest direct to rust

I also fixed my sloppy bush in the shock absorber

One step closer. Although still a few jobs left to do

[Tommyboy12]

Had more fun with the MGF. I took it for a short test drive after welding it and doing the bushes and I noticed two things. Firstly it needs a front wheel bearing. I'm getting Montego deja vu as it's the exact same wheel bearings making the exact same noise 😅

Secondly I sprang a leak in the cooling system. Water was dripping under the car when I returned home from the short drive. The temps didn't get hot but I'm not going to let a leak persist on a car with a marginal cooling system.

So began the inspection of the cooling system. I identified the culprit fairly quickly from the trail of water down the block. A crusty metal pipe with a pin hole.

Removing this pipe was a ball ache. It's bolted directly to the block under the inlet manifold with the engine look cable tied to it.

Finally got it free after what felt like an eternity. It's crusty and holey.

A stainless steel version is available which says it all but it's £160 and I don't want to pay that much so I've bought a £30 second hand steel one. This time the cars going back together with actual coolant in it. Water as a coolant is not enough!

[grogee]

On 8/17/2023 at 7:54 AM, Tommyboy12 said:

I'm getting Montego deja vu as it's the exact same wheel bearings making the exact same noise

Are they the ball-in-cage type or press-in type? I need to do the latter on the Maestro. Is it a pig of a job? The hubs will be off the car and I've got a press. 

[Tommyboy12]

1 hour ago, grogee said:

Are they the ball-in-cage type or press-in type? I need to do the latter on the Maestro. Is it a pig of a job? The hubs will be off the car and I've got a press. 

They're press in type. Getting the snap rings out was the most painful part as they had rusted into their groove. Pressed out and in an a press no problem though. I have it detailed earlier in this thread as I had to do it on the 1.3 Montego.

The Metro, Maestro, Montego, Rover 200, MGF/TF and Lotus Elise all share the same wheel bearing from the Montego. I believe it's fitted to a few other things too.

[Tommyboy12]

The cooling system is now back together on the MGF. Was a fairly easy task to get back together but I'm reminded that the cooling system is a pain to bleed. Also fitted a new thermostat, housing seals and new inlet manifold gasket. The hold gasket had sillycone on it of course...

Also fitted a new fuel filter. The fuel coming out the old one was basically black.

It's running and moving again and not leaking so now I need to get the wheel bearings done.

[Back_For_More]

My Forester did the same thing with the cross block under the inlet manifold coolant pipe too......  I took a couple of looks at it and bought 1m of coolant hosing - flipped the outlet in the header tank and slipped it through another route to the water pump. 

Wasn't sure I'd get away with it but 5 EU journerys and months later still all good so I'm not touching the sod. 

Great work on the MG. I've always shied from them due to the coolant/HGF horror stories tbf. Bottled it every time. 

A rotten old 'proper' mini though..... NOW you're talking 😁

Will you persevere with an original engine or go for a swap/upgrade? 

[Tommyboy12]

This is my fourth F/TF but unfortunately by far the worst so I'm used to the perils. I'm certainly used to the tight engine bays. Although there's certainly jobs I would rather not do like dropping the front subframe to change the bottom arms.

I've bought a manual engine for the Mini even though it's an auto. The auto is seized and autos in Minis have paper gaskets between the clutch packs so if it's sat with no oil or got water in it the box will be scrap pretty much. Morbid curiosity means I'll probably try and get it running on the floor.

[Tommyboy12]

Managed to get both functioning Minis out at the weekend. Firstly went to a local steam rally in the white Mini. It was 31C and she performed admirably without a hiccup.

Saw some interesting metal for those that are vaguely interested.

Then followed up on Sunday by going to Stanford Hall Mini Show in the turbo. It peaked at nearly 34C and taking the turbo was a poor decision in hindsight as it was far too hot for the borderline capable cooling system.

It did a little wee when we stopped after getting home having peaked at 140C oil temp. Too hot and that oil is now toast.

Ive bought myself a new larger radiator and a larger oil cooler. I will get these temps under control as best I can.

[Tommyboy12]

I've had a recent misfire on the Mégane. It came about late last week as I was giving a company director a lift to his hotel. I've never driven so gently to try and hide a car not running right once I realised what had happened 😅 Once home I plugged in my non-branded eBay special obd reader and it gave me a very insightful overview of the issue.

First up. Checked the spark and coils. This is cylinder 1. I found my issue very quickly. The seal failed on the pencil coil and let water in. Coil was wet and rusty. Bore full of corrosion and junk.

Funnily enough a new coil on cylinder one and a set of spark plugs for all of them and it runs great again! And my director is none the wiser of my half breakdown...

 

[sharley17194]

Moist

5 hours ago, Tommyboy12 said:

I've had a recent misfire on the Mégane. It came about late last week as I was giving a company director a lift to his hotel. I've never driven so gently to try and hide a car not running right once I realised what had happened 😅 Once home I plugged in my non-branded eBay special obd reader and it gave me a very insightful overview of the issue.

First up. Checked the spark and coils. This is cylinder 1. I found my issue very quickly. The seal failed on the pencil coil and let water in. Coil was wet and rusty. Bore full of corrosion and junk.

Funnily enough a new coil on cylinder one and a set of spark plugs for all of them and it runs great again! And my director is none the wiser of my half breakdown...

 

 

[Tommyboy12]

It's been a spell. Have an update!

Firstly I was meant to get my MGF ready for my annual pilgrimage to Scotland. This time round I was doing the Isle of Lewis and Harris as well as the NC500. The ultimate goal was to have the F ready for this but I failed. Rough wheel bearings and a lack of time prevented me from getting it ready in time. So instead I took my dad's MGF!

Unfortunately my girlfriend span out in a big puddle/lake on the motorway on the way home. The culprit was a tyre with no tread. Not something I thought I would need to check as it had only had an MOT a few days before we took it!

The damage wasn't major. A new bumper and tail light and a bit of panel massaging. Turned out there was also some rust under the bumper so I'll be cracking the welder out on it. My dad was very relaxed about it all thankfully 😅

Meanwhile my own MGF failed it's MOT on emissions and a loose battery.

Turns out I hadn't plugged in the lambda sensor after unplugging the engine loom to remove the inlet manifold. Plus I didn't tighten the battery strap. I'm an idiot... It's back in for retest this week.

Finally I have been doing some work to further control the temps on my turbo Mini. I treated myself to a thicker alloy radiator and I've gone from a 13 row oil cooler to a 19 row oil cooler.

Before

During featuring some top notch brackets.

After

This definitely didn't help on the old radiator..

But the new one is a bigger, thicker capacity with more fins and supposedly a better tube layout.

The oil cooler has much more airflow now as less of it is blocked by the intercooler. Temps seem better although that's helped by the weather cooling off also. I'm planning to get some electric fans to help out with things too.

[Tommyboy12]

Starting to lose the will to live on the MGF. It failed the emissions test again. Still ridiculously high at 9% CO. Seems the lambda might be toast and plugging it back in made no difference. I bought a new one and a catalytic converter (it already has some cheap aftermarket one fitted). Hopefully both those things sort it.

I also bought a pscan scanning tool for earlier MG Rovers/Landrover/etc. Covers all the pre-OBD2 compliant cars with an OBD port. I had someone come over and scan the car with their pscan tool and it gave a few fault codes but I feel bad asking them to come over again. Plus I know I have the Rover 400 (which I am yet to even collect, let alone look at) which will no doubt need it. This isnt my first, or last MGR product so it will no doubt come in useful again.

[Tommyboy12]

Well with the MGF continuing to depress me it's obviously the right time to buy another car to give me that sweet sweet hit of dopamine. So collection caper time!

Breakfast: TBD. Still in bed

Poo count: 0. As per above

Mode of transport to collection: Girlfriend's Hyundai i10. She has very kindly agreed to drive down with me so she can drive her car back and I don't leave it abandoned in the depths of Plymouth.

It's a hell of a drive this one.  So much so we decided to drive down last night and stay at a friends. It took 5 hours which wasn't bad considering the weather that was beating down yesterday. I suspect it will take slightly longer than this to get back based on the acquisition.

[Tommyboy12]

On our way! I'm really looking forward to this one. My first foray into this type of car. Hopefully the weather holds!

It's about 30 mins to collection

Breakfast: Fancy

Poo count: 1

Mode of transport: Ready to go!

 

[Tommyboy12]

I have arrived. It is magnificent