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Home > Show Us Yours! > '77 Clubman rebuild

robert

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uranus

blimey ..that is glossy.

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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Hungerford, Berks

Moving on from Glossy to matt…





Rather than creating a whole new grill from Carbon fibre and whatever else I would have needed to make the headlight surrounds, it seemed at the time more economical both time and cost wise to re-use the original aluminium grill with a few small modifications.

Well, it was not…
The grill was fairly out of shape and took a good chunk of work to get sorted.
Plus, it had been hacked about to fit the driving lights that were mounted in them:







One thing I am yet to decide on is the fixings.



At the moment I have the grill secured to the panel work with rivet nuts and M5 stainless steel button head cap screws, which looks ok, but I might yet be tempted to get some black anodised aluminium button heads….



Now you might be thinking “But it does not take a month to make a few modifications to an Alumiumin grill”, And you would be right…

For those of you that have read all of my previous pages of drivel, you might remember my trials with getting the front end to fit anything like well, and for those of you that have not read the rest of this thread, then 7th June 2020, 2/3rds of the way down page 4 will tell you all you need to know.


With all the work I had to do back then, I decided to mount up the new subframe and test fit everything again – So glad I did.



First off, the subframe would not bolt up level.
Apart from the fact that the threads on the old tower mount bolts were truncated and so I had to buy new, it appears that there is a quota of MIG wire to be use on each subframe, and as they had not used enough on the rest of the subframe, decided to use it on the top of the tower where the thread piece is welded in.



Not a very good picture, but the piece ringed in yellow.

On this photo, it looks nice and neat. On my subframe the fillet was at least twice as big and looked like the forest floor under a rookery.


No way the solid mounts were going over this massive pile of weld.
so I had to very, very carefully grind/ file out a load of weld until the mounts actually sat flat on the tower.

(By the time I thought “ooh, I should take a photo of this mess” it was too late and it already had a fresh coat of primer on it.)


Once the subframe was bolted in place correctly the next problem occurred.

“What, after all that work back in June – August 2020 the front end does not fit??? Why?”

Well, I have no idea, I can only assume that the main issue was either the old subframe I used at the time was out of shape, or the new one is out of shape.

Regardless, there was just no way the frontend was fitting.

And, once I did get it mounted in place, it was very evident that my plan around Brace bars was totally out the window.

On 9th Jun, 2020 Graham T said:

On 8th Jun, 2020 Nic said:
Looking good, despite the set backs of the front panel.

Regarding the brace bars; you have just reminded me that we welded on some plates to the side of the subframe to bolt the brace bar to. (I may be mistaken, these possibly also went to the side of the tie bar mount??)
The brace bar then went from this to the damper mount


Thanks Nic.
Seeing as I appear to have a gap between subframe and frontend bracket on the “better” side, I will probably bolt the brace bars to the front of the subframe to act as a spacer, but your method is always an alternative, depending on the final fit of the front panel.


The passenger side now has no gap between the front panel bracket and subframe at the bottom and a 4mm gap at the top (of the subframe front cross member). So the subframe is slightly out of shape, where as the driver side I still had the even gap that I had intended the brace bar to fit between.
So ultimately, I ended up having to make more modifications to the wings to get them to fit against the A Panel and I had change my idea’s on mounting the Brace bars.

Now I have ended up with this:



As yet I cannot actually make the bars up to the inner wing because I have no idea on clearance for the wheels and also the Damper hangers, so that will have to wait until the subframe is built and in place.



I the meantime, the next job is to complete the colour coat on the front end again so that it can go live back on my Spare bed for another indeterminate amount of time.

Edited by Graham T on 18th Jul, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


e5tus

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Dorset

That's a massive pain given the work that went into the front.

Yes to the black anodised fasteners, but you already knew that!


Graham T

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Hungerford, Berks



On 19th Jul, 2022 e5tus said:
That's a massive pain given the work that went into the front.

Yeah, frustrating, but hopefully now sorted.

On 19th Jul, 2022 e5tus said:

Yes to the black anodised fasteners, but you already knew that!


I have to admit I was swaying that way despite the massive costs involved - But I just wanted to see if anyone was awake out there *smiley*

Edited by Graham T on 19th Jul, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


robert

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uranus

gawdamighty !

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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Hungerford, Berks

A little more momentum now building up…

Started getting the paint on the body.
A little filler required on the rear quarter panels and some tiger seal in the seams, plus a little filler on the A panel and around the roof gutter.
Then some more epoxy primer




Followed by 2 coats of filler primer and a very light guide coat.
There was a little more build up and rub down on that rear quarter panel, but nothing too drastic.







The same with the front end






Then finally a solid coat.
Whoop whoop – its not all shades of grey, black and overspray and covered in 18months of grinding/rubbing down dust anymore – Finally it is green!!




I have to break out the small spray gun to try to get under the front scuttle. I have some missed areas around the bonnet hinge mounts where I did not plan my spray job very well – I could not get back under with the big gun without making a mess of the bulkhead on which I stupidly laid paint down first.
They do have a good coat or 2 of epoxy primer so I’m not worried about rusting, but I just know there are patches not green, so somehow I have to rectify that.








This is not a final coat though, I just wanted to get some gloss on the shell to see if there are area’s that need more work - Especially around the gutters which were a nightmare to get in shape.

As it stands though, the front end and driver side are good.
Now I just have the back end and Passenger side to do the same to before I tackle the inside.





Edited by Graham T on 11th Aug, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Graham T

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Hungerford, Berks

Rear End and Passenger side now in colour.











I was about to start on the massive clean up operation before moving onto the inside final coat, but then remembered the doors needed filler primer and colour coat ☹







One door in primer. Hopefully I should get it rubbed down and in colour tomorrow after work.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Yo-Han

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North of the Netherlands

Nice progress
So much work involved to get a good end result...

Dazed and Confused....


Graham T

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604 Posts
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Hungerford, Berks




On 16th Aug, 2022 Yo-Han said:
Nice progress
So much work involved to get a good end result...


Yes, there certainly is.
This is the part though that I least enjoy... And to think I am going to have to rub the whole thing down again *frown*

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Graham T

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Hungerford, Berks

Double post.

Edited by Graham T on 17th Aug, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Graham T

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Hungerford, Berks


Triple post *surprised*

Must be patient and resist urge to keep clicking "Post reply" .

Edited by Graham T on 17th Aug, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Jd24-7

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Worcestershire

Wow, some fantastic work and a man of many talents. from the roof gutter to electronics, you clearly have great patience and attention to detail. look forward to seeing this car going back together.
Great to see this kind of work coming out of peoples garages and sheds.


Graham T

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Hungerford, Berks

On 18th Aug, 2022 Jd24-7 said:
Wow, some fantastic work and a man of many talents. from the roof gutter to electronics, you clearly have great patience and attention to detail. look forward to seeing this car going back together.
Great to see this kind of work coming out of peoples garages and sheds.


Thanks.
“ Jack of all and Master of none” is a fairly accurate description I think…

I have been very fortunate to have had a lot of help and guidance from some very clever people over the years - most of them on here (at least they were in the past).

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


robert

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uranus

lovely colour .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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Hungerford, Berks




On 19th Aug, 2022 robert said:
lovely colour .


Gonna assume you are talking about the colour coat, which is Brooklands Green (HYF98 / BLVC1265), rather than the primer coat, which is primer grey with a hint of British racing green (gn29).

That was the third colour I tried (Brooklands). I originally thought it was too dark, but now I am pleased with it, especially now I have the matt black sorted for the door furniture, etc.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Rod S

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Rural Suffolk

Good to see you are still carrying on.
I lost interest and sidelined mine about 14 months ago once I collected my Cooper SE.
182HP in standard form from the factory and a petrol equivalent of approx 350mpg at my current overnight charge rate of 5p/kWhr with Octopus (although it goes up to 7.5p next month).
I'll probably get back in the garage this winter but not until I've installed a whole bank of solar panels on the roof....

Schrödinger's cat - so which one am I ???


Graham T

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Hungerford, Berks


On 29th Aug, 2022 Rod S said:

I'll probably get back in the garage this winter but not until I've installed a whole bank of solar panels on the roof....


We Had 21 off 410w solar panels fitted back in April (1 array of 10 on the garage roof and another array of 11 on the house).
We have pushed 2905kWh out to the grid so far and used about 350kWh.
If Scottish and Southern had got their act together, we might well have been able to sell some of what we have exported, but as it stands we are still waiting on a certificate (G99) to be able to get a feed-in tariff. Even then Octopus will only buy at a despicably low 7.5p per kWh.

The combined array output is supposed to be 8.4kWh, so we had to have a limiter fitted to stop the export going above 3.688kWh, so that 2905kWh export would have/ should have been much, much higher. Until Scottish and Southern get the certificate sorted, we cannot have the limiter remove either.



Also, because I was “umming and ahhing” about the expense for 2 days too long, all the batteries were sold out by the time I did place the order.
We finally got the Batteries last Monday (8.7kWh capacity) and since then we’ve only bought 7.6kWh from the grid and exported 80kWh (which we are not getting paid for.) – most of that which we have bought is me using the compressor in the evening.

So far it’s working fairly well, it will just be interesting to see how it actually performs as the days get shorter.

Edited by Graham T on 29th Aug, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Rod S

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Rural Suffolk

You have obviously gone into it in a much more serious way.
I've just bought 28 x 120W basic panels, the most I can fit on garage/house because of the chalet design of the house.
So 3.36 kW max.
The air source heat pump I've also bought is 3.28-3.62 kW electrical input for 14 -16 kW output so, because of its cyclic nature I should only need a small battery to balance the two.
No intention of exporting nor even connecting to the house, just to run the heat pump.
The capital outlay is horrendous, panels, cabling, batteries, inverters, heat pump, exchange cylinder, copper pipe, plumbing, etc. will never be re-paid in my lifetime but, hey, we love a challenging project !!!

Schrödinger's cat - so which one am I ???


Graham T

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Hungerford, Berks

So from green energy to Green shell.


Finally got the shell all in green, inside and out.





















It was a bit of a trying week with one issue where somehow I think I got a drop of Celly thinners in the paint ( I am thinking left over from cleaning the lid of the spray pot) – so I ended up with an interesting texture to the paint on part of the passenger B pillar which I had to flat out and redo.
Then I had a really bad finish to the clear coat on the backend, which I rubbed down again this morning and resprayed.

so that 2 coats of base and finished with 2 layers of clear coat.


There are a few lumps of crap in the paint, which I can hopefully polish out, and there is one annoying run which will need to be dealt with, other than that I am fairly happy with it.

Next step on the shell is to paint the roof black, which I hope to tackle on Sunday – I need to leave it alone tomorrow and give the paint time to harden before I try masking it all up.


Then it is finish coat on the doors and the bonnet to go…

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


shane

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Lowestoft, Suffolk.

Glad to see progress is still being made.
please keep the updates coming.

Shane


Graham T

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Hungerford, Berks

On 2nd Sep, 2022 shane said:
Glad to see progress is still being made.
please keep the updates coming.

Shane


Yes, progress is still being made, just slow…


So the last few weeks have been a mixed bag of success and mostly failure…

I got the Matte paint on the roof. It looked nice, but… it marks easily – too easily.
Press on it too hard or with a fingernail and you get a mark which cannot be removed.





So next attempt was to add a layer or two of Matte clear coat in hopes that it would be harder.
As I was about to use a Matte clear coat, I decided rather than waste the small amount matte Black paint I have left, I would use the satin black paint which I had for the subframes.
At this point I started getting little lumps of crap in the paint, so although the finish was much more resilient to touch, it just looked plain crap.
So I stripped the roof back, had a clean down in the garage and tried again - same thing, except some what worse…

(yes yes, typing it out now it is so obvious what the problem was, but at the time I just could not get my head around it, completely sure the issue was airborne dirt.)

After cleaning the gun, checking and replacing the filters in the airline, stripping the garage out and completely cleaning through - even nicking the floor mop from in the house and washing the floor down, then hoovering - I still had the same issue.

The problem is that with Matte paint, you can’t just polish out the little (and Large) bits in the paint, so it really is a pain in the arse.

I was on the verge of giving up and going gloss, which would have meant re-painting all the other bits I’ve done in the Matte Black and spoiling (in my view anyway) the theme of the car colour scheme.
Luckily, Dad to the rescue… “You need some tights”
WTF? he’s lost the plot…

“strain the paint with tights as you pour into the gun”.


Perfect (-ish) finally.
5 attempts later and I am happy with the finish.
Sue is not so happy that her tights are now not really wearable, but I am sure that deep down she is pleased that in some small way she has helped with the rebuild effort.


Anyhow, the Matte clear coat is not as matte as the matte black paint, but I can live with it.







That little episode has set me back another couple of weeks, so now I am frantically racing against the weather and time to get the rest of the panels painted.




I’ve made up a small frame to hold the doors while they were getting sprayed (yes, it more upcycling of that decking…)






Both doors are now finished






A little heavy with the clear coat, so I am now resigned to the fact that I am going to have to use the mop on the whole car – something I’m really not that keen in.


Just the bonnet, boot lid and front end left to go. Thankfully they are all prepped, so that should speed the process along a bit.


Edited by Graham T on 2nd Oct, 2022.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


e5tus

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Dorset

Looking great, glad you kept with the plan, I think the roof is great and the effort taken would have put most off.

Interesting old gem about the tights. Least some of this random but interesting information is being passed down!

Yes, mopping the car will be a PITA, but at this point given all the work, it's nothing. Keep it up!


robert

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uranus

will mop pretty easily i think graham , and well worth it .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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Hungerford, Berks

So just over 6 months later and I’m back on it.

For health reasons I have to take the winter off car building, because it just to darn cold in the garage - (Raynaud's disease).


Looking it over after 6 months, the paint work does need some work.
As well as needing mopping, there are a few spectacular lumps of shite that need to be sorted and a reaction of types on the passenger wing which I am still left to battle.


But for now, I am concentrating on getting the subframes built up.

A) Because I need my spare bedroom not to be a Mini parts store any longer
B) I need to get the wheels on to determine if I need an extensions on the wheel arches.
C) Because I really need to see some quantifiable progress


Subframe stripped back and painted with Epoxy primer and a top coat of satin black







Now, as normal, nothing could go right.
I mounted up the nearside radius arm.






And after a lot of faffing to get the toe and camber brockets fitted, torqued up the nuts and found it bound solid.
Stripped it back out, checked I had installed properly, confirmed I had not cocked up and tried mounting it up again.

Same thing – Even with the nuts just nipped up, it was bound hard.

Next step was to call in the reinforcements and get Dad to look over it.

He confirmed I had assembled it correctly.
After a short while of head scratching, the only conclusion we could come to was that the radius arm shaft must be too short.

I must point out at this point, that rather than doing the reconditioning of the radius arms myself, I bought recon units.
Checking the offside, we also found that it also bound when the nuts were tightened.
We took the arms to the local mini “specialists” that had done the reconditioning and checked the shaft length against some others they had in stock.
Their stock shafts varied in length by ~1mm shoulder to shoulder – those that were installed in my radius arms being the shortest of all we checked (by eye).
Eventually we found 2 shafts that fitted without any binding.

Pretty annoyed that they did not even do a basic check on the recon after they did it – like tightening up the nuts themselves to check...


Anyhow, after that disaster we got the subframe and backplates built up fairly quickly.










Before mounting in the car, I had a fight with the waxoyl spray gun, coated most of the garage in a fine film of waxoyl, then proceeded to coat/fill the gaps and crevasses in the subframe.

That done, the subframe was mounted, without too much swearing and loss of paint.












I am going to revisit the brake pipes on the radius arms. I thought the single piece braided goodrich hoses would be good, but I am not happy with the Heath Robinson method of securing with zip ties.





I think thats the easiest we have ever manged to fit a rear subframe.



New brake pipes made up and fitted












Then the part I have been waiting a long time to see.











The jury is still out.
I am not sure (and do not think I will be until the car is complete) as to whether I can live with the silver in the wheels.
A part of me says that the silver will help break up the green/ black combination, but another part of me says "NO, this is just wrong"...


Also, I think I can get away without adding arch extensions, but I realised that until I have the car on the floor and the toe, camber, ride height and whatever set up, I am not going to be able to see if the treads are "covered" enough to pass an MOT.





I need to read up on the rules again.



Anyhow, todays job is to start on the front suspension.



’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


shane

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Lowestoft, Suffolk.

Good to see some progress with this Graham.

Shane

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