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Old 18-06-2016, 09:33 AM   #1
Austinvti
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Default 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

Thats how it looked:





and this is my daily driver:



The pictures after the accident are speaking their own words
















Thats for the intro Lets get back to work:
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Old 18-06-2016, 09:42 AM   #2
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Default "cut out the twisted firewall"

this is where the story starts:

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



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

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





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



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



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Old 18-06-2016, 09:53 AM   #3
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Default Test fitted firewall

the old firewall was cut out:



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



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:



From now on i concentrated myself to cut ou the rusty footwell and replace it:




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Old 18-06-2016, 09:57 AM   #4
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Default milestone 1

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



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



Doors attached

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Old 18-06-2016, 10:16 AM   #5
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Default

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

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:





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:



positioned the engine:



And also made a first crossbar:



test:


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Old 18-06-2016, 10:26 AM   #6
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the towers allready finished:







Checking out were the screwing points must be tagged in:



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



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



test fit with engine in:





Not much space at the firewall:



area around the gearbox:



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

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Old 18-06-2016, 10:29 AM   #7
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Default "hey engine, hang in!"

building the engine mounts by using the original mounting points of the donor car:

















Finally:








And some details:













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Old 18-06-2016, 10:32 AM   #8
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Without engine and still without knot sheets at its state



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

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Old 18-06-2016, 10:42 AM   #9
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Default 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 ) and ended up with this:












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

with fitted pedals:



And also with a bit more space for the intake



finalised an rewelded with more current:

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Old 18-06-2016, 10:53 AM   #10
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Default 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:



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







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



tag it to the car:



and make some tests:











lets do this stuff to the passenger side:





ligning it up correctly:







still looks a bit messy but finish will follow asap

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Old 18-06-2016, 11:06 AM   #11
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I was not happy with the footwell so i replaced it and the inner wheels housings against rust free sheets of metal:












Played a bit with some ATS:









Doesnt look so bad
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Old 18-06-2016, 11:17 AM   #12
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Default whats under your skirt :)

to have better access to hidden areas i had t build a rotisserie for the van:

And i did so:









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 :/







Fiirst look



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

:



prepared for becoming closed soon

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Old 18-06-2016, 11:24 AM   #13
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Also added a new jagging point:



passenger side nearly finished:




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




removed rusty areas









under the loading area:



complete floor:



pipe area will be finished when my exhaust arrives
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Old 18-06-2016, 11:34 AM   #14
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Default 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).









cleaned from old paint:



underside detachable:



and electrics area:





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

Fusebox will get its own place
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Old 18-06-2016, 09:48 PM   #15
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Nice work
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