1600 16v long term project

webster444 · 07-09-2017, 07:14 PM

I have been building this car on and off for about 8 years now with no end in sight for the near future either! I recently found some photos of how it looked when I bought it so thought I'd throw a project thread together, unfortunately there are some photos missing but you get the idea.

Anyway, how it looked when I bought her, a £50 minter

A few of the many scars of tin worm

The first of many replacement panel deliveries

Then began the long job of cutting out rust and replacing, I almost threw in the towel after months of this

webster444 · 07-09-2017, 07:22 PM

At first my plan was to restore the mini to close to factory, I then thought that was too boring so the next plan was to build it with a few mods/fast road parts with a moderately tuned A series. I refurbished the subframes and began rebuilding.

After a break from working on it I needed some motivation, so after lurking in this forum for awhile I decided I would build a valver for track days & hillclimbs. So off came the front subframe and fabbed up a couple of bulkhead boxes

Went with a brand new Allspeed subframe, gave it a coat of hammerrite and transferred over the brakes, hubs etc from the old frame

webster444 · 07-09-2017, 07:36 PM

Engine wise I wanted to go with a C16XE as I have rebuilt and played about with these engines in the past. Unfortunately when I was looking for one I could not get one for love nor money so landed up with a x16xe which I proceeded to strip down.

Looks like this was previously owned by someone scared of the loud pedal

Block cleaned, re-honed & skimmed along with standard pistons pocketed for high lift cams

Rebuilt with new shells and ARP big end bolts

Managed to get a hold of a C16XE ported and polished head with new valve train

Head & block built up with Newman cams which were then dialled in

Bought a small alternator off a Suzuki or dihatsu, the pulley was damaged on arrival though

Decided to machine a new one up on the lathe

All built up in the frame with gearbox and homemade alternator bracket, I have also modified the standard pedal box to use two horizontal master cylinders

webster444 · 07-09-2017, 07:44 PM

Bought a set of 750 gsxr throttle bodies to use

Fabricated my own inlet manifold to suit the throttle body ports & head ports. A slight difference in port size between standard & my head

Thought I'd give fibreglassing a go and make some throttle body trumpets. I made a plug out of timber on the lathe

Not bad for first attempt, the chips are due to the difficulty in releasing from the plug

Made up a fuel rail out of a bit of aluminium

1 litre polo rad fitted -just

webster444 · 07-09-2017, 07:58 PM

The last few days work - built up the throttle bodies and run in the fuel lines, radiator also plumbed in

Standard size front hides it all, just

andyfkettle · 07-09-2017, 09:36 PM

Nice work. I've been on mine longer than I care to think about but the end is in sight!

keep it going.

ardonfast · 08-09-2017, 02:23 AM

your on it ,, like a car bonnet!!
you havent filled in much about you, what do you do for a job?

webster444 · 08-09-2017, 11:20 AM

Quote:

Originally Posted by ardonfast

your on it ,, like a car bonnet!!
you havent filled in much about you, what do you do for a job?

I work offshore, used to be a mechanic but now spend most of my time out there behind a desk off the tools!

gadget555 · 09-09-2017, 08:55 AM

Nice work Webster444 you have some good skills, keep up the good work and the updates, where about's in the shire are you? as I'm in Strichen.

webster444 · 09-09-2017, 09:35 AM

Cheers! Im out the back of Inverurie at Meikle Wartle

ardonfast · 10-09-2017, 01:30 AM

Quote:

Originally Posted by webster444

I work offshore, used to be a mechanic but now spend most of my time out there behind a desk off the tools!

good job your off tools, makes you burn for this lol, worth poping into see
keithgadget,, compair notes ect

MattG · 15-09-2017, 01:53 PM

looking good

webster444 · 18-09-2017, 11:14 AM

Found out my original fuel tank is scrap so used that as an excuse to buy an aluminium one and got the fuel pumps and swirl pot plumbed in.

Bought myself a mini all in one dash, designed for bikes buy should do the job in the mini

Purtsi · 20-09-2017, 07:12 AM

I have the same Koso dash in my Mini. Works and looks great!

webster444 · 24-10-2017, 04:16 PM

Latest update on the mini, made a fibreglass dashboard and switch panel which will allow me to crack on with the wiring.

Constructed the moulds from MDF and used body filler to get the radiuses, then varnished and coated with release wax

Black gelcoat applied

Couple of layers of fibreglass matting applied and cured

And the finished article, multi dash added to see how it sits. Switch panel still to be drilled for the various switches required.

07-09-2017, 07:14 PM	#1
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	1600 16v long term project I have been building this car on and off for about 8 years now with no end in sight for the near future either! I recently found some photos of how it looked when I bought it so thought I'd throw a project thread together, unfortunately there are some photos missing but you get the idea. Anyway, how it looked when I bought her, a £50 minter A few of the many scars of tin worm The first of many replacement panel deliveries Then began the long job of cutting out rust and replacing, I almost threw in the towel after months of this

08-09-2017, 02:23 AM	#7
ardonfast Senior Member Join Date: Oct 2011 Location: dunkeswell airfeald devon Posts: 7,779 Subframe: AMT CC: 2000 Make: Vauxhall ECU: dizzy/webers	your on it ,, like a car bonnet!! you havent filled in much about you, what do you do for a job? __________________ "yuck ,more like a 3 r2" http://www.youtube.com/watch?feature...&v=tb261HwQNDQ SAY WHAT YOU BELEVE,,BELEVE WHAT YOU LIKE, http://www.youtube.com/watch?feature...&v=3JhaTwP7uuk

15-09-2017, 01:53 PM	#12
MattG Administrator Join Date: Sep 2003 Location: West Sussex,UK Posts: 7,305 Subframe: Allspeed CC: 2000 Make: Vauxhall ECU: Megasquirt	looking good __________________ Mini Restoration on YouTube VW camper in storage , Red hot , www.16vmini.co.uk www.jetblackmini.co.uk Dad's Building K1100 : bmw.16vmini.co.uk , donate to club running costs : paypal@16vminiclub.com

20-09-2017, 07:12 AM	#14
Purtsi Senior Member Join Date: Apr 2008 Location: Finland Posts: 1,063 Subframe: Other CC: 1300 Make: Suzuki ECU: Megasquirt	I have the same Koso dash in my Mini. Works and looks great! __________________ I have a cunning plan...

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07-09-2017, 07:22 PM	#2
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	At first my plan was to restore the mini to close to factory, I then thought that was too boring so the next plan was to build it with a few mods/fast road parts with a moderately tuned A series. I refurbished the subframes and began rebuilding. After a break from working on it I needed some motivation, so after lurking in this forum for awhile I decided I would build a valver for track days & hillclimbs. So off came the front subframe and fabbed up a couple of bulkhead boxes Went with a brand new Allspeed subframe, gave it a coat of hammerrite and transferred over the brakes, hubs etc from the old frame

07-09-2017, 07:36 PM	#3
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	Engine wise I wanted to go with a C16XE as I have rebuilt and played about with these engines in the past. Unfortunately when I was looking for one I could not get one for love nor money so landed up with a x16xe which I proceeded to strip down. Looks like this was previously owned by someone scared of the loud pedal Block cleaned, re-honed & skimmed along with standard pistons pocketed for high lift cams Rebuilt with new shells and ARP big end bolts Managed to get a hold of a C16XE ported and polished head with new valve train Head & block built up with Newman cams which were then dialled in Bought a small alternator off a Suzuki or dihatsu, the pulley was damaged on arrival though Decided to machine a new one up on the lathe All built up in the frame with gearbox and homemade alternator bracket, I have also modified the standard pedal box to use two horizontal master cylinders

07-09-2017, 07:44 PM	#4
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	Bought a set of 750 gsxr throttle bodies to use Fabricated my own inlet manifold to suit the throttle body ports & head ports. A slight difference in port size between standard & my head Thought I'd give fibreglassing a go and make some throttle body trumpets. I made a plug out of timber on the lathe Not bad for first attempt, the chips are due to the difficulty in releasing from the plug Made up a fuel rail out of a bit of aluminium 1 litre polo rad fitted -just

07-09-2017, 07:58 PM	#5
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	The last few days work - built up the throttle bodies and run in the fuel lines, radiator also plumbed in Standard size front hides it all, just

07-09-2017, 09:36 PM	#6
andyfkettle Senior Member Join Date: Jun 2010 Posts: 437	Nice work. I've been on mine longer than I care to think about but the end is in sight! keep it going.

09-09-2017, 08:55 AM	#9
gadget555 Senior Member Join Date: Jan 2011 Location: Strichen Aberdeenshire Posts: 1,316 Subframe: Watson CC: 1800 Make: Rover ECU: K maps 160 Race	Nice work Webster444 you have some good skills, keep up the good work and the updates, where about's in the shire are you? as I'm in Strichen.

09-09-2017, 09:35 AM	#10
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	Cheers! Im out the back of Inverurie at Meikle Wartle

18-09-2017, 11:14 AM	#13
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	Found out my original fuel tank is scrap so used that as an excuse to buy an aluminium one and got the fuel pumps and swirl pot plumbed in. Bought myself a mini all in one dash, designed for bikes buy should do the job in the mini

24-10-2017, 04:16 PM	#15
webster444 Member Join Date: Aug 2014 Location: Aberdeenshire Posts: 43 Subframe: Allspeed CC: 1600 Make: Vauxhall ECU: Soon to be megasquirt	Latest update on the mini, made a fibreglass dashboard and switch panel which will allow me to crack on with the wiring. Constructed the moulds from MDF and used body filler to get the radiuses, then varnished and coated with release wax Black gelcoat applied Couple of layers of fibreglass matting applied and cured And the finished article, multi dash added to see how it sits. Switch panel still to be drilled for the various switches required.