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-   -   D16Z6 Leyland Van - reloaded - (http://www.16vminiclub.com/showthread.php?t=36496)

Austinvti 18-06-2016 09:33 AM

D16Z6 Leyland Van - reloaded -
 
After loosing my whole build thread, it took a while to reanimate it.

Thx to the reliability of photobucket its good to have least my pics online, yet.


I dont want to copy my old thread the same way but still want to decribe everthing as good as i can ;)

lets get started:


The reason for building a second VTEC Mini was a desastrous accident in the late fall of 2010. I drove my restored Van for a unbelieveable term of 3 months untill crashed :mad:

Thats how it looked:

http://i1036.photobucket.com/albums/...z.jpg~original

http://i1036.photobucket.com/albums/...o.jpg~original

and this is my daily driver:

http://i1036.photobucket.com/albums/...o.jpg~original http://i1036.photobucket.com/albums/...x.jpg~original

The pictures after the accident are speaking their own words :(

http://i1036.photobucket.com/albums/...x.jpg~original


http://i1036.photobucket.com/albums/...v.jpg~original

http://i1036.photobucket.com/albums/...y.jpg~original

http://i1036.photobucket.com/albums/...i.jpg~original

http://i1036.photobucket.com/albums/...3.jpg~original

http://i1036.photobucket.com/albums/...q.jpg~original

http://i1036.photobucket.com/albums/...l.jpg~original

Thats for the intro :) Lets get back to work:

Austinvti 18-06-2016 09:42 AM

"cut out the twisted firewall"
 
this is where the story starts:

cutted off all the rusty (did i said i restored the van??:rolleyes:) and twisted parts.

http://i1036.photobucket.com/albums/...a.jpg~original

But first did a lot of measurements compared to non demolished minis.

area of the window (for the hight of the "new" firewall):

http://i1036.photobucket.com/albums/...z.jpg~original

http://i1036.photobucket.com/albums/...v.jpg~original

And also whats the width of the car to ensure there is no siude compression after the accident:

http://i1036.photobucket.com/albums/...o.jpg~original

After alot of measurements, it was time for some stiffeners in the shell and let the angle grinder do its job:

http://i1036.photobucket.com/albums/...t.jpg~original

http://i1036.photobucket.com/albums/...4.jpg~original

Austinvti 18-06-2016 09:53 AM

Test fitted firewall
 
the old firewall was cut out:

http://i1036.photobucket.com/albums/...k.jpg~original

and the donored firewall had to be prepared for its first practical test:

http://i1036.photobucket.com/albums/...y.jpg~original

Sadly i tagged it in to soon after finding out that it was 5mm off the center of the car :((

But after some swearing and sweating: it cam to this result:

http://i1036.photobucket.com/albums/...w.jpg~original

From now on i concentrated myself to cut ou the rusty footwell and replace it:
http://i1036.photobucket.com/albums/...s.jpg~original

http://i1036.photobucket.com/albums/...4.jpg~original

http://i1036.photobucket.com/albums/...c.jpg~original

Austinvti 18-06-2016 09:57 AM

milestone 1
 
Finaly (thats the moment i thought i reached a big milestone) it was in and i can go to other construction areas:

http://i1036.photobucket.com/albums/...2.jpg~original

First shot with the subframe in and some old "new" fenders attached:

http://i1036.photobucket.com/albums/...n.jpg~original

Doors attached :)

http://i1036.photobucket.com/albums/...m.jpg~original

Austinvti 18-06-2016 10:16 AM

From this point i had a look (and a second one...) to the doors fitment, which was also at the first "restoration" a mess.

Beside the gaps, there is also - what every MK1/2 driver knows - always a contact with the b- pillar.

So i went into myself and decided to go for suicide doors instead of usting the outer hinges.

The outer hinges will stay as unfunctional accessoire because of maintaining the old look as good as it is even possible :D

But before i talk about the doors, i have to say i was a bit jittery or should i say nervous by thinking of how i made the front subframe:

So i let the thoughts about the doors by side (i will post it here) and started with the frame build:

5h after getting the donor car it ended like this:

http://i1036.photobucket.com/albums/...k.jpg~original

:)

i bought a used frame out of an mgf 1.8 without vvc so the engine wasn`t interesting to me :)

After receiving my springs from Oli (aka Mr.Cooper) i checked out how high the "towers" must be:

http://i1036.photobucket.com/albums/...x.jpg~original

positioned the engine:

http://i1036.photobucket.com/albums/...e.jpg~original

And also made a first crossbar:

http://i1036.photobucket.com/albums/...y.jpg~original

test: :)


http://i1036.photobucket.com/albums/...z.jpg~original

Austinvti 18-06-2016 10:26 AM

the towers allready finished:

http://i1036.photobucket.com/albums/...r.jpg~original

http://i1036.photobucket.com/albums/...l.jpg~original

http://i1036.photobucket.com/albums/...o.jpg~original

Checking out were the screwing points must be tagged in:

http://i1036.photobucket.com/albums/...z.jpg~original

And a first side view on the front axle 8still with mgf brake discs:

http://i1036.photobucket.com/albums/...q.jpg~original

how many space is in the front after clamping in the missing piece that it allready look like a mini ;)

http://i1036.photobucket.com/albums/...a.jpg~original

test fit with engine in:

http://i1036.photobucket.com/albums/...8.jpg~original

http://i1036.photobucket.com/albums/...e.jpg~original

Not much space at the firewall:

http://i1036.photobucket.com/albums/...w.jpg~original

area around the gearbox:

http://i1036.photobucket.com/albums/...3.jpg~original

Lifting up the engine by using honda car lifters is easy if you can`t use a professional engine lifter. Also it allows to lign up the the engine more precisely ;)

http://i1036.photobucket.com/albums/...1.jpg~original

Austinvti 18-06-2016 10:29 AM

"hey engine, hang in!"
 
building the engine mounts by using the original mounting points of the donor car:

http://i1036.photobucket.com/albums/...c.jpg~original

http://i1036.photobucket.com/albums/...3.jpg~original

http://i1036.photobucket.com/albums/...b.jpg~original

http://i1036.photobucket.com/albums/...9.jpg~original

http://i1036.photobucket.com/albums/...4.jpg~original

http://i1036.photobucket.com/albums/...w.jpg~original

http://i1036.photobucket.com/albums/...h.jpg~original



Finally:


http://i1036.photobucket.com/albums/...h.jpg~original

http://i1036.photobucket.com/albums/...n.jpg~original

http://i1036.photobucket.com/albums/...d.jpg~original

And some details:

http://i1036.photobucket.com/albums/...0.jpg~original

http://i1036.photobucket.com/albums/...7.jpg~original

http://i1036.photobucket.com/albums/...d.jpg~original

http://i1036.photobucket.com/albums/...m.jpg~original

http://i1036.photobucket.com/albums/...k.jpg~original

http://i1036.photobucket.com/albums/...a.jpg~original

http://i1036.photobucket.com/albums/...t.jpg~original

Austinvti 18-06-2016 10:32 AM

Without engine and still without knot sheets at its state

http://i1036.photobucket.com/albums/...c.jpg~original

Also attached some footwellplates to screw the frame to the car:

http://i1036.photobucket.com/albums/...p.jpg~original

Austinvti 18-06-2016 10:42 AM

How to brake
 
Now it was time to rethink about the brake and its booster. Screwing up the booster in its common way - straight forward - was not part of my plan. i have to say that the most parts of "my ideas" were stolen from Mr.coopers website and also from his threat about the rally van:

from him i got the hint to set the brake booster upside down so i had to doi some cuts into the firewall (not again :( :( :twisted:) and ended up with this:

http://i1036.photobucket.com/albums/...w.jpg~original

http://i1036.photobucket.com/albums/...a.jpg~original

http://i1036.photobucket.com/albums/...0.jpg~original


http://i1036.photobucket.com/albums/...0.jpg~original

http://i1036.photobucket.com/albums/...3.jpg~original

The reservoir will be replaced against some motorcycle brake fluid reservoires.

with fitted pedals:

http://i1036.photobucket.com/albums/...c.jpg~original

And also with a bit more space for the intake :D

http://i1036.photobucket.com/albums/...k.jpg~original

finalised an rewelded with more current:

http://i1036.photobucket.com/albums/...c.jpg~original

Austinvti 18-06-2016 10:53 AM

Lets talk about the doors
 
a big question was it, what kind of hinges can i use to
a) maintain the old hinges (but without the joint pins inside)
b) make it possible that the doors swing outside while rotation around its joints

So i went to my computer and asked Madame CATIA - well known as katja - how can i realize that:

have to build a box like this:

http://i1036.photobucket.com/albums/...a.jpg~original

and after some try&error on my "virtual van" it shows that my idea will work:

http://i1036.photobucket.com/albums/...z.jpg~original

http://i1036.photobucket.com/albums/...d.jpg~original

http://i1036.photobucket.com/albums/...n.jpg~original

So back in the garage, lets do it in real:

http://i1036.photobucket.com/albums/...f.jpg~original

tag it to the car:

http://i1036.photobucket.com/albums/...h.jpg~original

and make some tests:

http://i1036.photobucket.com/albums/...w.jpg~original

http://i1036.photobucket.com/albums/...f.jpg~original

http://i1036.photobucket.com/albums/...j.jpg~original


http://i1036.photobucket.com/albums/...0.jpg~original


lets do this stuff to the passenger side:

http://i1036.photobucket.com/albums/...l.jpg~original

http://i1036.photobucket.com/albums/...v.jpg~original

ligning it up correctly:

http://i1036.photobucket.com/albums/...s.jpg~original

http://i1036.photobucket.com/albums/...7.jpg~original

http://i1036.photobucket.com/albums/...e.jpg~original

still looks a bit messy but finish will follow asap

http://i1036.photobucket.com/albums/...q.jpg~original

Austinvti 18-06-2016 11:06 AM

I was not happy with the footwell so i replaced it and the inner wheels housings against rust free sheets of metal:


http://i1036.photobucket.com/albums/...p.jpg~original

http://i1036.photobucket.com/albums/...m.jpg~original

http://i1036.photobucket.com/albums/...r.jpg~original

http://i1036.photobucket.com/albums/...a.jpg~original

http://i1036.photobucket.com/albums/...h.jpg~original

Played a bit with some ATS:

http://i1036.photobucket.com/albums/...v.jpg~original

http://i1036.photobucket.com/albums/...p.jpg~original

http://i1036.photobucket.com/albums/...y.jpg~original

http://i1036.photobucket.com/albums/...q.jpg~original

Doesnt look so bad :)

Austinvti 18-06-2016 11:17 AM

whats under your skirt :)
 
to have better access to hidden areas i had t build a rotisserie for the van:

And i did so:


http://i1036.photobucket.com/albums/...y.jpg~original

http://i1036.photobucket.com/albums/...l.jpg~original

http://i1036.photobucket.com/albums/...n.jpg~original


Next step on the plan were the outer sills. they were not vented and i saw some brown chrome on it. me and my grinder are a good team. so why not cutting it out :/

http://i1036.photobucket.com/albums/...k.jpg~original

http://i1036.photobucket.com/albums/...z.jpg~original

http://i1036.photobucket.com/albums/...s.jpg~original

Fiirst look :(

http://i1036.photobucket.com/albums/...f.jpg~original

but after cleaning with wire, it doesn`t look so bad :)

http://i1036.photobucket.com/albums/...n.jpg~original:

http://i1036.photobucket.com/albums/...g.jpg~original

prepared for becoming closed soon

http://i1036.photobucket.com/albums/...8.jpg~original

Austinvti 18-06-2016 11:24 AM

Also added a new jagging point:

http://i1036.photobucket.com/albums/...3.jpg~original

passenger side nearly finished:

http://i1036.photobucket.com/albums/...f.jpg~original


Also i added some place for the exhaust (side pipe?):


http://i1036.photobucket.com/albums/...n.jpg~original

removed rusty areas

http://i1036.photobucket.com/albums/...r.jpg~original


http://i1036.photobucket.com/albums/...0.jpg~original

http://i1036.photobucket.com/albums/...9.jpg~original


under the loading area:

http://i1036.photobucket.com/albums/...m.jpg~original

complete floor:

http://i1036.photobucket.com/albums/...a.jpg~original

pipe area will be finished when my exhaust arrives

Austinvti 18-06-2016 11:34 AM

What about the dash?
 
I cut out the old dashboard and put it over a 1 inch tube bar.

the tube is detachable and the whole dashboard will get a sandwich like finish to hide all the electrics, ecu and not so beautiful stuff ;)

So i ended with this (details will follow).

http://i1036.photobucket.com/albums/...j.jpg~original


http://i1036.photobucket.com/albums/...z.jpg~original


http://i1036.photobucket.com/albums/...p.jpg~original

cleaned from old paint:

http://i1036.photobucket.com/albums/...8.jpg~original

underside detachable:

http://i1036.photobucket.com/albums/...y.jpg~original

and electrics area:

http://i1036.photobucket.com/albums/...e.jpg~original

http://i1036.photobucket.com/albums/...s.jpg~original

the height is nearly the same like the ecu (which is the highest thing to hide)

Fusebox will get its own place :)

leon 18-06-2016 09:48 PM

Nice work :)


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