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Mk1 Minter

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Post by jas_racing Tue Feb 05, 2013 4:48 am

**Started this project thread last April but hadn't updated it since May so thought I'd re-write and add to it on here as I've done a fair bit to it since then**

Bought the 'car' via eBay - advertised as a "fully restored bodyshell with parts to reassemble". After investigating it appears the chap had bought it in 1996 as a running car but it had issues, namely electrical, engine, gearbox and rust. He stripped it in 1997, the body was restored by a local classic car restoration place and completed in 2000, but then was returned to the owner and stored for 12 years or so without anything being done to it until I came along. The owner had bought a HEAP of new OE parts (new front bumper, seat covers, rear brake calipers, engine bay heat shield, front fogs, decal kit, dozens of clips, connectors and fasteners to name but a few). The bodyshell had a new bonnet, both doors, front panel, inner wings, chassis legs, sills, floors, inner & outer rear arches and rear-panel. It was then treated to an inside-and-out paint job.

As I bought it:
Mk1 Minter P1040021
Mk1 Minter P1040024

In-situ on my drive:
Mk1 Minter P1040033

Inside:
Mk1 Minter SAM_1589
Mk1 Minter SAM_1588
Mk1 Minter SAM_1591

Engine bay:
Mk1 Minter SAM_1600

Initially I spent my spare time & free weekends building a car port to put her under but then expected to be able to crack on putting her back together. However, despite me thinking otherwise when I had a poke around under the rear of the car it turned out that this "fully restored" bodyshell had a fair bit of surface rust. Upon further investigation it seems that the rear end was still sporting the original factory-applied underseal and the restoration place had done (seemingly) nothing to strip or reapply it. I therefore spent many, many hours lying on my back scraping and brushing all effected areas. I was concerned at first that some of it would need welding but despite getting into literally every nook & cranny there was nothing more than surface rust, with nothing perforated or rusted through. I therefore took all effected areas back to bare metal then treated with POR-15 (clean/prep/paint) then topped off with 2 coats of waxoyl.

During:
Mk1 Minter SAM_1724_zps1d916662

After:
Mk1 Minter SAM_1763_zps1a081772
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Post by jas_racing Tue Feb 05, 2013 5:12 am

The jacking points needed treating too:
Mk1 Minter SAM_1772_zps1a3896ea

Floors are totally solid otherwise (it seems that the old jacking points were welded to the new floors and cover in underseal without any pre-treatment).

The inside of the (new) front wings that had just started bubbling up:
Mk1 Minter SAM_1774_zpsa150f44b

These were treated & POR-15'd...never figured why bodyshops seem to miss such detail when painting a car? The thin black coating that comes on new panels has virtually zero corrosion resistance yet most bodyshops seem to paint only the outside Question Even areas of minor corrosion bother me greatly so I figured it was best to spend as much time as was needed getting everything 100%. Whilst sorting the rear floor and chassis rails I filled every cavity, the sills, front chassis rails, inside the rear arches, etc, with 2 coats of Dinitrol. This car won't ever be used in the rain but just in case I want to be sure it's well protected, even if it took me several months to achieve!

Rear arches looking good: (note that the car is sitting on a home-made trolley at this point)
Mk1 Minter SAM_1764_zps0c356e94

FINALLY I got on to actually bolting something back on the car - (new) rear top strut mounts:
Mk1 Minter SAM_1786_zps95b67ce8

Plan of attack was to refit the rear suspension and rear beam. I bought a full set of new -40mm lower dampers & springs:

Old vs. new:
Mk1 Minter SAM_1794_zps6206bb01
Mk1 Minter SAM_1792_zps1f2953ae
Mk1 Minter SAM_1793_zps5edc5843

However, I wasn't happy with the dampers being yellow so rubbed them down & painted them a more 'tasteful' satin black:
Mk1 Minter SAM_1833_zps24ef1d42

Rear springs with refurbed caps/rubber mounts:
Mk1 Minter SAM_1832_zps7b87c0d7

Rear beam had already been powder-coated by the previous owner so it was just a matter of assembling with new bushes & refurbed brackets:
Mk1 Minter SAM_1840_zps9d9421a6
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Post by vern Tue Feb 05, 2013 5:23 am

Awesome work mate she will be mint when finished, what's the plans for the engine ?
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Post by jas_racing Tue Feb 05, 2013 5:24 am

Mounting to car:
Mk1 Minter SAM_1842_zps02ef1d45

Original bump stops fitted within new springs:
Mk1 Minter SAM_1872_zpsaef190c5

Dampers attached:
Mk1 Minter SAM_1873_zpsf70e7c8c

New hubs/bearings:
Mk1 Minter SAM_1877_zps9944c745

Temporary steel wheels fitted:
Mk1 Minter SAM_1848_zpsa86982f5

Back on terra-firma on two wheels at long last: Smile
Mk1 Minter SAM_1849_zps145b599e

Moving to the front I bought new wishbones & anti-roll bar mounts but wasn't happy with their lack of corrosion protection so rubbed them down & painted them with numerous coats of aerosol Hammerite:
Mk1 Minter SAM_1852_zpsc5fc7194
Mk1 Minter SAM_1861_zps62f77ba6
Mk1 Minter SAM_1862_zps6de226c8
Mk1 Minter SAM_1863_zps1f279edc

With rubbed down & POR-15'd brackets:
Mk1 Minter SAM_1864_zps4497e10c
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Post by jas_racing Tue Feb 05, 2013 5:38 am

New front dampers painted satin black:
Mk1 Minter SAM_1898_zpsd973be26

Top mounts needed a bit of work:
Mk1 Minter SAM_1879_zpse6d582b4

New OE bearings added:
Mk1 Minter SAM_1892_zpsd1700c69
Mk1 Minter SAM_1894_zpse12a3b4d
Mk1 Minter SAM_1895_zps9309dcae
Mk1 Minter SAM_1897_zps6fa06bc4

Assembled & ready to fit:
Mk1 Minter SAM_1915_zps7efdfcd2

Front hubs looked pretty rough to start with but actually turned out very nicely:
Mk1 Minter SAM_1900_zps9b0262ab

Cleaned up & rubbed down:
Mk1 Minter SAM_1903_zps3fa172ac

Ready for POR-15ing:
Mk1 Minter SAM_1906_zps2f11ee4f

Painted: (I added 2 coats of aerosol Hammerite after this)
Mk1 Minter SAM_1909_zps1c47fd66

New SKF bearings fitted:
Mk1 Minter SAM_1935_zps28f6e681

Front inner hubs/flanges needed tarting up:
Mk1 Minter SAM_1913_zpsaebfee6c
Mk1 Minter SAM_1934_zps440702c0

New front subframe has been powder-coated:
Mk1 Minter SAM_1923_zps6456bae2

Assembly off-car:
Mk1 Minter SAM_1924_zpsc4e5057b
Mk1 Minter SAM_1925_zps937cff9c

Stripped & re-painted ARB added:
Mk1 Minter SAM_1926_zps2d936706
Mk1 Minter SAM_1930_zpse4a3804c

Bolting whole lot to car:
Mk1 Minter SAM_1932_zpsf2b9b2f0
Mk1 Minter SAM_1933_zpsa953bee0

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Post by jas_racing Tue Feb 05, 2013 5:46 am

Adding hub & damper:
Mk1 Minter SAM_1938_zpsea9e3937
Mk1 Minter SAM_1940_zps15476b72

Wheel on:
Mk1 Minter SAM_1941_zps3f8d90de

Other side:
Mk1 Minter SAM_1942_zps7bd384fa

Back down on 4 wheels: Very Happy
Mk1 Minter SAM_1944_zpsdf2d0704

I've also refurbed the brake compensator valve housing (brand new valve):
Mk1 Minter SAM_1858_zpsfcad8a21
Mk1 Minter SAM_1859_zps6e8f048f

All fasteners are stainless and in some cases custom-made/special order in high-tensile stainless where needed Cool

That's all for now, moving onto the brakes next (new copper-nickel pipes have been made) although I have also just about finished refurbing the fuel pump cradle. Will try to update a bit more often from now on!
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Post by jas_racing Tue Feb 05, 2013 5:52 am

vern wrote:Awesome work mate she will be mint when finished, what's the plans for the engine ?
Thanks and the engine will be standard other than a Forge recirculating dump valve, I've got my Coupé 20VT for speed purposes Wink
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Post by robr33gts Tue Feb 05, 2013 6:08 am

top work mate she will b like new makes me want to crack on with mine even more would love to see this Very Happy
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Post by hakydan Tue Feb 05, 2013 10:10 am

Lovely attention to detail, trust me, it takes a while but the results are defo worth it. Im nearing the end of my now 2 year build and I still walk out of the garage with a huge smile on my face. Well done Smile
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Post by Unograle Tue Feb 05, 2013 10:15 am

Great to see this thread revived Jase, TOP MAN !!! Very Happy

Loving the attention to detail, your shell deserves nothing less mate.
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Post by gtirx2 Tue Feb 05, 2013 10:31 am

Looking good mate,i do enjoy seeing them come together like this and look forward to the future updates Cool

Thats the trouble with these cars they do hide there rot well, especially if someones been there before you.
Looks like you have caught it in time though as leaving that hiding under there is asking for trouble.

I can also appreciate the work involved in cleaning that area up aswell,proberly one of the most fiddly and time comsuming parts on the car,well worth the effort though and it looks to have came out sweet Smile .
The other place worth checking if you have not already is all the way along the back of the inner sills,if its still in it original underseal it might be worth just stripping it off along there each side and redoing it.

Parts are coming out great,you guys get on much better with the hammerite than i do Crying or Very sad ,i may try the aerosols next time as the finish looks really good compared to what i end up with it looking like with a brush Laughing

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Post by jas_racing Tue Feb 05, 2013 11:20 am

Thanks for the comments guys Smile

It's taking a lot longer than I thought, especially as I only really work on it every other weekend when my daughter's not with me, but I'd rather take my time if it means a top job in the long run. I've not stopped even in the cold weather though, just wrapped up warm with a hat & mechanics gloves. My general aim is to get everything except the engine & 'box done before next winter, then work on them over the winter ready to drop in and (hopefully) fire up spring 2014!

Even with the brand new parts (such as the wishbones, track rod ends, etc) I'm not comfortable just bolting them on as is, so I've been painting them up to try and stop them rusting in the long run. Not that it will affect their performance or safety in service necessarily, but I don't want to take a wheel off one day and see some bits still nice and shiny but others rusting.

gtirx2 - the back of the inner sills are sorted mate, all solid & very well protected. And yeah all those nooks and crannies under the back end are ridiculously fiddly, I lost count of how many hours I spent laying under it, often 'til midnight! There were times when I got pretty cheesed off with doing it but I'm glad I did. Aerosol Hammerite comes out very thick and only gives good results if applied very lightly in multiple coats then hung somewhere warm to cure I've found.

It was quite a moment when I lowered it off the jack and onto 4 wheels for what was probably the first time in 15 years! Just ordered some stainless steel split-pins for the handbrake pulley wheel Laughing
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Post by charliemk1 Tue Feb 05, 2013 12:19 pm

Very nice nut and bolt job mate.. The only way to do it properly I think
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Post by richvans Wed Feb 06, 2013 8:21 am

Top Job man, gona be a nice build to follow Very Happy do like the mk1's

I see you polybushed the anti roll bar, this made a massive difference on mine reducing body roll, leaving new rubbers on the other bushes will make it less harsh ride - good plan as it'll be too nice to risk on a track !
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Post by jas_racing Wed Feb 06, 2013 11:42 am

richvans wrote:I see you polybushed the anti roll bar, this made a massive difference on mine reducing body roll, leaving new rubbers on the other bushes will make it less harsh ride - good plan as it'll be too nice to risk on a track !

Erm...I didn't have much option as I couldn't find the right standard rubber bushes for the inner ARB mounts so just went for Superflex ones in the end Embarassed

I didn't want to use polybushes for the rear beam either but again I couldn't find any standard rubber ones until after the Powerflex ones had arrived in the post Rolling Eyes
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Post by jas_racing Wed Feb 06, 2013 12:08 pm

OK, in the spirit of regular updates...

I stumbled across an issue the other day in terms of the rear hubs/wheel bearings - in the pile of parts that came with the car were a brand spanker pair in their boxes so I assumed they were the right ones but upon trial fitting the caliper brackets I quickly realised they weren't. It seems that the previous owner fell into the trap of being told that all Uno's use the same ones when they don't. After a scout around the 'net I found that only First Line list the turbo ones as a different part from all other Uno's and 68mm deep not 62mm. Thankfully I found some of the right ones for a mere £14 each online.

A quick rub-down, mask and ready for spraying (being bare metal there's no way they were going on as-is):
Mk1 Minter SAM_1948_zps25872cf0

Done: (in silver Hammerite)
Mk1 Minter SAM_1960_zpsad5a34e7

Some brackets I rubbed down, rust treated & POR-15'd a couple of weekend's ago: (are they intercooler related?)
Mk1 Minter SAM_1959_zps9a871b34

Fuel pump cradle is coming along - started off looking pretty grotty:
Mk1 Minter SAM_1868_zpse17ced67

Had to use an angle grinder with a 1mm thick cutting disc to get the old rubber mounts & weld-nuts off. Brackets were rubbed down, rust treated, POR-15'd then top-coated with Hammerite (aerosol):
Mk1 Minter SAM_1950_zps09bce900

Bought new rubber mounts, pump, pipe, primary filter, stainless fasteners and (of course) stainless jubilee clips:
Mk1 Minter SAM_1952_zps6e33137d

Bracket assembled:
Mk1 Minter SAM_1954_zpsf956a155

Pump & filter in-situ (still need to put a rubber strap around the fuel pump clamp):
Mk1 Minter SAM_1956_zps8b707d6c

Passenger side top strut mount/plate is looking much better after a bit of work:
Mk1 Minter SAM_1919_zps25e3e4d9
Mk1 Minter SAM_1921_zps761d7f3d
Mk1 Minter SAM_1958_zpse6eee3e4

New front brake shields came in the pile of parts with the car but again I wasn't happy with the lack of corrosion protection so they were rubbed down & painted with 4 coats of Hammerite black (aerosol):
Mk1 Minter SAM_1881_zpsc2d30baa

I've also started on refurbishing the rear window hinges/latches: (metal parts will be painted satin black)
Mk1 Minter SAM_1946_zps78a085fc

Bought new stainless screws to put them back together with and secure the triangular plate to the C-pillar but have painted the heads satin black so as not to stand out:
Mk1 Minter SAM_1963_zps1d1eaebd

That's all for now Smile
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Post by robr33gts Thu Feb 07, 2013 7:37 am

the bracket mate are like you say the top two in the pic are intercooler the bottom right oil cooler not sure bout bottom left maybe oil cooler to but my oil cooler bolted one side to the same bracket as the intercooler and the other side was the same as the bottom right bracket
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Post by jas_racing Thu Feb 07, 2013 8:59 am

robr33gts wrote:the bracket mate are like you say the top two in the pic are intercooler the bottom right oil cooler not sure bout bottom left maybe oil cooler to but my oil cooler bolted one side to the same bracket as the intercooler and the other side was the same as the bottom right bracket
Thanks dude Smile It's funny, as I didn't strip the car some of the parts in the many boxes are a mystery to me so I just pick them out, clean/treat/paint 'em then put them to one side thinking "I'll figure out what that does or where it goes at some point in the future". Looking at photos of other Uno's is helping a lot too! Cool
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Post by robr33gts Thu Feb 07, 2013 9:10 am

im like that some times and i striped mine lol its a bit worrying at times my memory is really bad tho just hope i can remember when i come to rebuild it
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Post by robr33gts Fri Feb 08, 2013 12:06 pm

where did you find the standard rear beam bushes mate been looking for some for ages
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Post by robr33gts Sat Feb 09, 2013 5:04 am

cheers mate more expensive than i thought tho might go for powerflex ones after all
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Post by jas_racing Sat Feb 09, 2013 7:48 am

Yeah if you're not concerned with staying OE then the purple Powerflex versions are better value as they're more or less the same price but perform considerably better in service
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Post by jas_racing Sun Mar 31, 2013 9:24 am

Hi Guys,

Another update for y'all - nothing major mind, what with the weather being so lousy I've not been able to take any major steps forward as I'd hoped but plenty of little bits & pieces done:

Finished of the rear window catch & screws (I had to buy M3.5 screws & nuts to replace the rivet pins I'd drilled out then paint 'em satin black) -

Mk1 Minter SAM_1965_zps3dd9edf7

Assembled & fitted -
Mk1 Minter SAM_1966_zps446f170a

Refurbed front shock top plates fitted -
Mk1 Minter SAM_1969_zps0c1b821f
Mk1 Minter SAM_1970_zps156363dc

I also discovered that the new rear hubs that came with the car were wrong as they are non-turbo, so after a bit of searching I found some correct turbo ones & ordered them. Pic shows non-turbo on the left, turbo (painted up ready to fit) on the right -
Mk1 Minter SAM_1973_zpse79f5d56

I set to work on the rusty & gunky steering rack -
Mk1 Minter SAM_1975_zpsb2c388c5

Rack cleaned up & ready for painting (I did also strip, clean & regrease the rack internals but have no photos) -
Mk1 Minter SAM_1978_zpsdff09600

Painted & reassembled with new rack ends, track rod ends & gaitors -
Mk1 Minter SAM_2016_zps5c53ace7

Rack/gear linkage bracket took a bit of cleaning up and the little swivel cranks were seized solid initially but it all looks good now after a couple of coats of POR-15 then 2 more of Hammerite aerosol -
Mk1 Minter SAM_2008_zpsf590f3e2
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Post by jas_racing Sun Mar 31, 2013 9:49 am

Cleaned, rubbed down & painted the servo & steering column -
Mk1 Minter SAM_1993_zpsf0d9ad13
Mk1 Minter SAM_1992_zps1569d911
Mk1 Minter SAM_1996_zpsdd10351c
Mk1 Minter SAM_2002_zpsf15c2049
Mk1 Minter SAM_2013_zps5df3dfa7

Also painted the new master cylinder & mated it with the servo -
Mk1 Minter SAM_2015_zpsb14103a1

Caliper carriers/brackets are finished & ready to fit after a rub down & paint (with POR-15) -
Mk1 Minter SAM_2011_zpsfc184f00
Mk1 Minter SAM_2012_zpse3dcf301

Intake pipes rubbed down, primed within an inch of their lives, rubbed down again then treated to 4 coats of 'tough' gloss black -
Mk1 Minter SAM_1995_zps561eaa32
Mk1 Minter SAM_2027_zps247f6d8b
Mk1 Minter SAM_2124_zpsd77633d9
Mk1 Minter SAM_2127_zps30b36f63
Mk1 Minter SAM_2125_zpsdd602c27
Very pleased with how these have turned out, given their prominence in the engine bay Smile

I decided that the scuttle panel & pillars needed painting again so did so with satin black then I could fit the windscreen -
Mk1 Minter SAM_1984_zps25c18158
Mk1 Minter SAM_1983_zpsf4004406
Mk1 Minter SAM_1985_zps058451de

Fitted the interior bulkhead insulation panel (steering column/shaft is also fitted in this pic) -
Mk1 Minter SAM_2129_zpsc0c5340a

New front brake shields fitted -
Mk1 Minter SAM_2025_zps72e07692

Heater box fitted (I also screwed on the top center console but it'll be off again at some point to be cleaned up properly) -
Mk1 Minter SAM_2135_zps3dcc9a45

I've also fitted new boot & front door seals plus the window seals & guides (but didn't take any photos) so the car is now effectively water tight.

That's all for now, I'm currently working on refurbing the gear linkage & handbrake lever/mount then next up is the pedal box/beam assembly Smile
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