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Mearcat 4E-FTE Clubman Build (Latest update 5-05-24 Pg 28) https://www.ausmini.com/forums/viewtopic.php?f=23&t=60133 |
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Author: | Mearcat [ Fri Jan 08, 2010 9:57 pm ] |
Post subject: | Mearcat 4E-FTE Clubman Build (Latest update 5-05-24 Pg 28) |
Note : There is much more detailed info about the build, hints, tips, info for the stripping the Mini & Starlet etc at my blog of the build at http://mearcat.blogspot.com Consider this ausmini thread an abridged version of the blog If you have any questions at all, don't hesitate to PM or email me. It all started when I regretfully sold my semi-restored 1972 Clubman 3 years ago to help pay for a good chunk of our wedding (2 years ago). My wife fell in love with our old Mini so when the question was soon posed whether I could restore another one, she jumped at it. Yaaaay After much discussion with my wife and then research, we decided upon the (well known to many) 4E-FTE Toyota Starlet GT engine conversion. So the story begins 18 months ago, July 2008, when the purchase was made... I found a 1978 Clubman in Bunbury, W.A. owned by a 17yo guy who had mostly stripped the shell and some of the engine - with intentions of doing an engine conversion of sorts but for various reasons, did not go through with it. Overall the shell was in good condition but with only a couple of concerns - the rear valance corner had a hole you could put your fist through, the front valance was severely dented had enough bog in it to sink a ship and a hole in the passenger side sill. it had been on the market for 5 months and no-one seemed to want a half-stripped shell & half stripped engine so for the measly sum of $1000, it was mine. Another 5 hour trip from Perth to Bunbury & back was in order, this time with a trailer. Unfortunately, we were half way through building our new house at this time so once it transported to Perth, the Mini was stored at a mate's garage for the next 6 months. Once our house construction was completed, I moved the Mini to it's new home and at the same time, found a very neglected '75 Clubman (for $100) which had been out in a paddock with no glass or panels fitted, exposed for at least 2 years and quickly rusting away - The panels there was more holes and rust than straight steel and there was nothing special about the serial numbers. I wanted to strip this for some random parts and cut the shell in half so the front half could be used as a test rig for trial fitting the modified subframe & drilling any holes/brackets I may need. The plan is that Starlet engine and all ancillaries will be fitted to the white Mini and when completed, duplicated in the other Mini. For many months, both cars sat collecting dust while I finished a huge list of things in the house, the workshop, workbench, spray booth and still more house stuff. My workbench didn't stay clean for long March 2009 rocked around and got a chance to see and drive what was the only (that I know of) legal Starlet GT engine conversion in Perth. James ('77 Clubby Van on ausmini) drove the 650km from Kalgoorlie to Perth to get the engineers' (pre-registration) inspection completed. I drove it, was suitably impressed even though it wasn't really in tune. But it was when he had a few spirited runs against my 305rwhp Nissan Skyline R33 (mid 13sec 1/4 mile car) when I realised that the 4E-FTE conversion in a Mini would be a ball tearer of a car James has since moved back to Victoria so once complete, my Mini will be a unique one in Perth. It was the motivation I needed to get started... I stripped the rusty white Mini to bits, gave away the siezed engine, pulled off the various parts that I needed and dumped the rest at the scrap yard. Sara could now park her car in the garage for the first time. Needless to say, she was a happy chap. |
Author: | Kennomini [ Sat Jan 09, 2010 11:40 am ] |
Post subject: | |
That spit is the same design as one of mine. The rear bolts onto the seat belt holes up top, but where dose your bottom section bolt onto? |
Author: | hallsey [ Sat Jan 09, 2010 2:58 pm ] |
Post subject: | |
Top job on the spit AL , that will make life so much easier. I had to roll mine onto some mattress's and tyre's, while it worked the spit is much easier and more accessable. Good work AL Cheers Hallsey |
Author: | Mearcat [ Sat Jan 09, 2010 6:50 pm ] |
Post subject: | |
Kennomini wrote: That spit is the same design as one of mine. The rear bolts onto the seat belt holes up top, but where dose your bottom section bolt onto?
To be honest, I think it might have been your spit design which I got inspiration from The bottom section of the rear piece bolts through the shock absorber holes. I still have to weld some tabs (or holes) to allow the due to be locked into place while it's semi-rotated. |
Author: | Smarty [ Sat Jan 09, 2010 10:00 pm ] |
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Looks like a pretty good shell for the project, cant wait to see the progress. |
Author: | Kennomini [ Sun Jan 10, 2010 1:04 am ] |
Post subject: | |
Yeah the spit attaches the same as mine, I've sat in it grinding and haven't noticed any flexing in the shell or the spit so IMO it should be fine Also when your done with the donor clubby nose you can convert it into a BBQ . |
Author: | d1ck0 [ Sun Jan 10, 2010 8:28 pm ] |
Post subject: | |
Looks Good Alan, and loved reading the blog too. Your link above has a dot in the wrong place so doesnt work properly (the dot after the .com). http://mearcatmini.blogspot.com/ should work though. Cheers, Dicko |
Author: | Mearcat [ Mon Jan 11, 2010 10:42 am ] |
Post subject: | |
A few little things have also happened on the side in the last couple of months as well... I got a set of 5 12x5" Performance Superlite mags second hand, suffering from a bad case of gutter rash and various scratches. These were cleaned up, sanded back where necessary and esnt off for sandblasted and powdercoating. I asked for a bright silver powdercoat and got a primer grey colour instead! Needless to say, a few whines and whinges later and he knocked $50 off the price. Which I promptly spent on new paint for them. Some final light sanding to get some dust & crud out of the powdercoat, a few coats of paint and few coats of clear and here they are in a Ford Machine Effect silver (has a slight blue pearl through). They sparkle once out in the sun (but not like those stupid Twilight movie vampires ) I also purchased a set of Metro brakes (I actually bought these before I even had the Mini!), replaced the Metro hubs with Mini hubs and got them all sandblasted, painted in high-temperature enamel silver (calipers) and satin black enamel (hubs, drive flange etc). New stainless steel pistons and a seal kit were put through them last weekend. I have also created a How To for installing the seal kit http://www.ausmini.com/forums/viewtopic.php?t=60165 The Metro hubs in this pic were sold and replaced with Mini disc hubs |
Author: | blue_deluxe [ Mon Jan 18, 2010 10:34 pm ] |
Post subject: | |
That is a pretty large hole. Im glad im starting out with a clean shell. Can you buy a replacement panel for that? or is it going to be custom? (and you should put the pictures upside down and see what people say about a floating angle grinder) |
Author: | Mearcat [ Tue Jan 19, 2010 12:01 am ] |
Post subject: | |
blue_deluxe wrote: That is a pretty large hole. Im glad im starting out with a clean shell.
Can you buy a replacement panel for that? or is it going to be custom? It was a shock when I found it because you just couldn't see the plates welded over the big hole until I scraped the thick layer of body sealer off. I didn't even notice it when I thoroughly checked over the car when I bought it. The rest of the shell is actually pretty good (he says before the shell is blasted ) Yes you can buy the inner A panel for both sides (eg. http://www.minisport.com.au/prod894.htm) which replaces the hinge reinforcement area which has rusted away completely, but it involves lining up the door mount holes properly. Since I'm getting it deseamed at the same time, it may be easier to weld in the replacement panel vs custom work. I'll find out which way is easier when I get to the panel beater ... hopefully in a few months |
Author: | MiniKit [ Tue Jan 19, 2010 9:54 pm ] |
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Holy crap and I thought the hole in Hetty was big.. Nice progress your making there Alan.. |
Author: | JC [ Thu Jan 21, 2010 8:10 pm ] |
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Hey Alan, good progress. What are you using for a jig to make the subframe? I have made the mistake of using a mini front cut - I wouldn't recommend it. |
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