Project Mini: 1961 Morris Mini Minor

[supersonic]

I've seen similar fuel filters used in minis that i saw in one beetle here in Pakistan. Cone shaped body with the inlet and outlet aligned. Inexpensive but not so easily available in Canada or i'd bring some back with me.

For the motor i managed to find an 850 cc in lahore and at the time i was lucky enough to find it because ever since, my search for finding original A series motors in both lahore and rawalpindi have been fruitless. Nevertheless i overhauled the engine, rather assisted Ustad Javed of Mini fame from pindi using parts procured through him and from a resourceful stockist/supplier in lahore. Didnt find new pistons even after hard research so ended up just putting in new rings and sleeves. New Water pump which has already been replaced once as it broke while running the engine in. the rest was in pretty good shape.

The transmission hasnt been tested out actually since the engine didnt have a gear lever installed. We just moved the gears around with a makeshift lever to check if they were jammed or not. They werent so all was good. New hoses for brakes and clutch etc, new radiator since i didnt have an original one before. New fan too, metallic but im looking for a lighter plastic or perhaps vinyl version. Refurbished carburettor, i have two acually and am looking for the twin carb manifold. Ive heard that they are a nightmare to synchronise but i still want to see how it goes. I Have a larger single carb off of a 1000cc too just in case that doesnt work and I still want more performance. The setup shall be tested this summer insha Allah and then we'll know for sure.

[razaksyed]

Fixing the original (metal) fan is not a good idea considering the heatup issues. In fact you may have to install two fans a plastic one on the engine pully and an electric type on the grill behind the rediator to suck the hot air out from the lest wheel side. The transversally mounted engine tends to heat up quickly as the hot air takes a while to escape creating a hot air cocoon in the engine bay.

So you already know Javed (Jedy) in Tunch Bhatta Rawalpindi. Just a caveat, recheck every part acquired through him. I just dont trust this gentleman.
Best of luck with the resto.

[razaksyed]

the vw fuel filters are available dime a dozen in Pakistan, will cost you 4 times more in Canada. Would you be able to grab (if your baggage permits), a tin of "Nevrdull" chrome polish from Canadian Tire? Needless to mention, I will pay whatever it would cost you.

[razaksyed]

I am assuming you already have technical material on hand. You can count on me for borrowing the Haynes Manual for photo copying... just in case.

[supersonic]

Fixing the original (metal) fan is not a good idea considering the heatup issues. In fact you may have to install two fans a plastic one on the engine pully and an electric type on the grill behind the rediator to suck the hot air out from the lest wheel side. The transversally mounted engine tends to heat up quickly as the hot air takes a while to escape creating a hot air cocoon in the engine bay.

So you already know Javed (Jedy) in Tunch Bhatta Rawalpindi. Just a caveat, recheck every part acquired through him. I just dont trust this gentleman.
Best of luck with the resto.

I found an unused metal fan so i've put that in for now, looking for other suitable replacements though. As for the second fan, i've found its a smart thing to do to battle the high temperatures in Lahore. My '76 Mini had one installed which gave me the idea to do the same on this one. I'm also thinking of installing a small oil cooler upfront if space permits.

Jedi is knowledgeable and experienced plus he knows all the old players who have parts etc so he is very useful but theres only a handful of people in this world that i trust blindly. Sadly he does not give off the same aura. I'm looking for someone honest and fair in his dealings regarding minis in rawalpindi, so far Moqeem is the closest i've gotten but he takes quite some time to dig up parts etc.

[supersonic]

the vw fuel filters are available dime a dozen in Pakistan, will cost you 4 times more in Canada. Would you be able to grab (if your baggage permits), a tin of "Nevrdull" chrome polish from Canadian Tire? Needless to mention, I will pay whatever it would cost you.

Great, then i'll get a dozen soon when i get back. As for the polish, thankyou for reminding me that i need finishing products for my cars as well. Your request set off a chain reaction to search for appropriate polishes etc.

It shouldnt be a problem to get a can or two, but you're in rawalpindi if im not wrong?

I would love to get any material you have copied for myself, keeps me from getting bored. And backs me up in discussions with old experienced players.

[supersonic]

The Boot Setup 'before'

The boot lid had been replaced, probably because the original one has corroded away, boot lids on minis are highly prone to rusting from the bottom and hence rot away from the hinges up leaving nothing useful.

the shape and form of this lid was poor to say the least, the signature depression for the number plate was missing, infact it was just a cover so to speak to close the boot compartment.

This is what an original boot lid looks like. Notice the details and curvature which is not uniform but has different gradients at the edges than at the centre.

The boot lid is actually made of two separate pieces of metal, one is the outer cover while the second is the frame or skeleton that gives it strength and rigidity. Once complete they are put together to give the final shape. the lid is upside down in this picture.

Notice the corrosion on the bottom of the lid, the area around the hinges has been cleaned for repair. The lid is upside down in this picture.

[razaksyed]

I come from Islamabad but the NevrDull could reach me by DAEWOO or courier; else I could perhaps arrange pick up from your place, if that is convenient for you. The part of world I work (Liberia) is so remote, even common brands like Turtle Wax are never heard of leave alone a chrome polish. I do transit in Dubai but hardly get the time or left with any energy to go out shopping.

If you are in Toronto, the Candian Tire outlet on Younge Street had a good range of finishing products. If my ropey memory serves me well, this was next to Petro Canada Gas Station few intersections north of bloor, while heading towards steels avenue. Home Hardware was another good option when I was there many years ago. I am sure you would know more. I should stop talking like a geezer now.

[supersonic]

Behold, the Masterpiece, from a simple sheet of metal, Ustad Zahid crafted an exact replica of the original boot lid. The pictures say more than my words ever can.

The Magician!

Outer side:

Inner side, the small dents that you see are due to the repetitive hammering and will be smoothed out when the final touches are being done.

Skeleton, Notice the intricate curves that have been copied exactly as they were on the original. Brilliant handiwork.

[dr3ad555]

@supersonic.
Amazing this is man!

[razaksyed]

@ Supersonic,
Your denter is simply amazing and surely deserves to be paid well for the superb piece of work done so far. Many denters back here are reckless iron beaters.

[overspeed111]

great project bro.....

[supersonic]

I come from Islamabad but the NevrDull could reach me by DAEWOO or courier; else I could perhaps arrange pick up from your place, if that is convenient for you. The part of world I work (Liberia) is so remote, even common brands like Turtle Wax are never heard of leave alone a chrome polish. I do transit in Dubai but hardly get the time or left with any energy to go out shopping.

If you are in Toronto, the Candian Tire outlet on Younge Street had a good range of finishing products. If my ropey memory serves me well, this was next to Petro Canada Gas Station few intersections north of bloor, while heading towards steels avenue. Home Hardware was another good option when I was there many years ago. I am sure you would know more. I should stop talking like a geezer now.

I'm in Montreal but i know where the Canadian tire store near me is. What type of work do you do that takes you from Pakistan to Canada to Liberia?

[supersonic]

Ustad Zahid is the best denter i have seen so far. His work takes time and a lot of money mind you but in the end it is simply exquisite. If he didnt have the trademark denter illness of delaying long term projects in favour of a quick buck he would have my sworn allegiance.

Money is an issue, as i like to warn fellow pakwheelers, do NOT take up a project like this unless you have 3-4 lacs in your pocket. Or you'll end up delaying the project like me.

[daniyalahmad]

Great piece of work by the denter (Y)
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[razaksyed]

@Supersonic,
Canada was for education, others including Liberia have been mainly work related (social development / humanitarian assistance).

[supersonic]

@Supersonic,
Canada was for education, others including Liberia have been mainly work related (social development / humanitarian assistance).

where did you study and which faculty?

[supersonic]

Both the inner piece and the out cover of the boot lid have been put together, and no one can tell that its been fabricated. Looks just like a new one.

Outside, all the necessary holes have been drilled for the number plate and lamp cover.

Inside, The frame fits perfectly into the cover. the sides have been sandwiched together and sealed.

Note the detail on the housing made for the boot lock. Edges at different levels that look as if they were made from a die cast.

[supersonic]

The rear end of the car had faced a similar fate as the front. The rear lights were originally the small round ones but the previous owner had switched to the rear lights off of a suzuki bolan, adding another car from the suzuki family into this achar.

The rectangular holes cut into the body were crude to say the least and had later been covered in half a centimetre of putty so the fitting/orientation of these 'NEW' lights was skew.

You've already seen the replacement boot lid and its effortless build which made it more like a flat piece of metal with rounded edges. Of course it clashed with the subtle curve of the rear end that was originally present and this could surely not be tolerated by those executing a brilliant modification. But it was too much trouble to make the boot cover round and seemed much easier to pick up a sledge hammer and beat the curve into a flat submissive contour. This whole damage had to be reversed and the rear end underwent reconstructive surgery before the newly fabricated bootlid could go on.

Some pictures 'BEFORE'

Note the flat contour of the bootlid.

The rear end had been flattened to meet the requirements of the bootlid and this shows to the naked eye.

A closer look at the flat contour that had been enforced. You can notice on the upper part that a section in the middle has been crudely flattened with a hammer. The wavy metal gives the secret away. The cracks on the bottom part are surface cracks in the half centimetre layer of putty.

[supersonic]

Separating the rear apron and the rear end. the boot floor had already been removed. These three layers are sandwiched together eventually.

Using an oxyacetylene flame or 'batti' to burn through the paint and loosen/remove the joints and welds.

Most of the rusted metal just melts and falls apart leaving voids on the edges. this makes it hard to reconstruct the edges as they originally were but we were lucky to have another mini around in better shape so we took our measurements off of it.