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Old 26-07-2017, 05:28 PM   #1
ZA-J
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Good evening all,

I thought it was about time I started a build thread on here.....I blew up my supercharged A Series gearbox on new years day, and have spent a load of time researching and deciding what route I wanted to take after that.

I've now decided on VVC power courtesy of a ZR 160. The donor has been bought, stripped and scrapped and the engine is sort of in the hole left by the A Series!

One big must is standard roundnose - I don't like the look of an extended front, so Mini based subframe is the way forward.

Pictures tell a thousand words:
MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr

MG Mini by Andy Walker, on Flickr
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Old 26-07-2017, 05:32 PM   #2
ZA-J
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Loom cut and shut
MG Mini by Andy Walker, on Flickr

Ready to start making it fit!
MG Mini by Andy Walker, on Flickr

Mock up subframe in
MG Mini by Andy Walker, on Flickr

Plenty of sparks
MG Mini by Andy Walker, on Flickr

Offering it up
MG Mini by Andy Walker, on Flickr

Nearly sits in the hole (just blocked up on the wood)
MG Mini by Andy Walker, on Flickr

Need to sort some clearance issues before starting to cut the 'real' subframe (I only replaced original front subframe with a heritage unit 90 miles before the A series gearbox went bang!) and welding some box section in.
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Old 26-07-2017, 06:32 PM   #3
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Welcome and looking good so far, keep up the good work and the photos
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Old 26-07-2017, 06:38 PM   #4
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Great work so far!!! you did a proper job on that A series gearbox!!
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Old 27-07-2017, 06:04 AM   #5
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A man after my own heart. Doing this due to chocolate Mini gearboxes. Don't get Shaun going on that subject again...

Looking good so far.
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Old 27-07-2017, 04:12 PM   #6
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Originally Posted by AGoaty View Post
A man after my own heart. Doing this due to chocolate Mini gearboxes. Don't get Shaun going on that subject again...

Looking good so far.
whats there to say that is (A) chockolate box
4th dont do out eather ,
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Old 27-07-2017, 04:18 PM   #7
ZA-J
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Thanks chaps. It made a hell of a bang when it went!.......nothing to do with the 'spirited' driving on a slightly damp road

I'm sure there'll be plenty of questions over the coming weeks......currently trying to decide which alternator to use for mocking up! Seems a small denso/Nippon is most common one at the mo.
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Old 27-07-2017, 07:10 PM   #8
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I have a small denso one from a four track to go on mine with a home made mount.
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Old 28-07-2017, 09:59 AM   #9
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Good start!

I'm sure you'll do lots of reading about frame building, but try and get the engine/box good and central. It'll help with the weight distribution, and stop you lighting up the passenger side wheel every time you set off.
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Old 02-08-2017, 12:10 AM   #10
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Good start!

I'm sure you'll do lots of reading about frame building, but try and get the engine/box good and central. It'll help with the weight distribution, and stop you lighting up the passenger side wheel every time you set off.
Yep. Read through every thread where they've built a frame, pick out all the best ideas. I did that, then improved on my son's design. I still made mistakes and I'd make it differently if I were to do it again. My thread's here - read pages 1 & 2 to see the frame development and modifications.
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Old 03-08-2017, 11:21 AM   #11
ZA-J
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Thanks asahartz - very helpful! Hopefully there'll be some more progress this weekend.
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Old 18-08-2017, 09:17 AM   #12
ZA-J
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Made a bit more progress recently - started chopping the subframe we're going to use (a 90 mile old heritage subframe!) and working out where the new iron is going in.

Untitled by Andy Walker, on Flickr

Has anyone kept tie rods in the original position with a VVC? Must have biased the engine over to the passenger side?

Untitled by Andy Walker, on Flickr

Checking wheel clearances before welding bits of subframe back in!

Untitled by Andy Walker, on Flickr

Last edited by ZA-J; 18-08-2017 at 09:20 AM.
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Old 18-08-2017, 05:02 PM   #13
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Has anyone kept tie rods in the original position with a VVC? Must have biased the engine over to the passenger side?
I think it can be done if you design the lower rails to kick in at the front. If I were building my frame now I would do that.



The pic above shows my lower side rail as I've made it; if I angled the front end in the way the back end kicks out, then the tie rod mount should stay in its original position.

This frame looks as though it achieves that too:
http://www.16vminiclub.com/showpost....postcount=2390

As regards positioning the engine, I found it was limited by the gearbox clearance against the towers. Plus you don't want the driveshaft to be too short; they're short enough as it is!
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Old 19-08-2017, 05:19 AM   #14
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Nice looking project and great progress, I'm watching with interest. Your front bar is quite high, and very close to the engine, guess you are you planning the exhaust manifold in front of the frame? Not seen anyone doing that. From what I've found so far (mine part way through build), tie bar position is a headache.... offsetting to the gearbox side as you mention you would have to go quite a long way and on mine would cause tyre rub on full steering lock. Yours might be ok with you big offset wheels, but the weight will be too far over I should think. To keep standard width between front mountings you need to kick the front of the frame in as asahartz said. But then you have to attach the bars below the frame because they slope down towards the lower balljoint and would otherwise come into contact with the wider part of the frame. The further back you can mount the engine, the easier the angles get. The Allspeed frames appear to have the tie bars mounted lower than standard and wider apart, supplying cranked tie bars to avoid tyre rub. With any luck someone who has finished a frame of their own will chime in soon......


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Old 20-08-2017, 08:02 PM   #15
ZA-J
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The tie bar cannot physically make the standard position on mine without hitting the sump. Looks like I'm going to have to kick them out about 10mm. Height will be the same to keep the angle on the bottom arms as near to standard as possible. I can't get the engine any further back - the bulkhead has already been cut to gain a bit more space and the gearbox is pretty much touching the steering rack.

The front bar is at that height to keep it behind the front panel. The bracket inside the curve of the front panel for the front subframe mount has been cut out so the bar sits right along the front of the front panel. Theres more than enough room to get the exhaust through there - not exactly sure what manifold I'm going to use yet...whether it's a full custom job or cut and shut the standard ZR unit. We shall see.
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