Warning : Lots of pics in this post
I've managed to get a few bits & pieces done in the last month - steering column mods & seat mounts
I wanted to retrofit as much of the Starlet gear as I can in the Mini to make the wiring easier - this includes the combination switch assembly for the wipers, lights, indicators etc as well as the ignition barrel which therefore need to be mounted onto the Mini steering column. The Mini steering column is smaller in diameter than the Starlet so like everything else, a custom bracket was used.
On the EP82, the bracket which mounts the main switch assembly in the Starlet is actually welded to the steering column so this had to be cut off.
Even though the Mini does have a steering lock mechanism, the Starlet ignition barrel will be mounted higher up the column than the Mini one so the Starlet locking pin won't be used and was ground off.
To allow the ignition barrel to bolt around the smaller Mini steering column, I simply welded in some half tube on one bracket (on the right bracket in pic below) and then made another piece to sandwich between them (middle piece in pic below).
For the plastic cover to fit around the switch assembly and ignition barrel, the switch assembly and ignition barrel had to be a specific distance and angles to each other so a section of tube was welded between the two factory pieces.
Before the gear shifter position is determined, I needed to find out where the seats would go. I had previously purchased a pair of near new 2nd Gen (~2007) Suzuki Swift seats which provided a reasonable amount of lumbar support and are quite comfy.
Standards (boring but important stuff) :
The Dept of Transport in WA specifies that the seats have to adhere to the national Vehicle Standards Bulletin (VSB 5B) which says 25mm x 25mm x 2mm RHS is to be used for making a supporting frame for a seat from another vehicle but I decided to use a beefier 32mm x 4mm flat bar with appropriate gusseting for the mounts.
The standards also specifically state that where the mounts are affixed to an un-reinforced section of the floor pan, each attachment point must be reinforced by the use of a plate of not less than 50mm x 50mm x 3mm thick. Sliding seat mounts must also have a minimum of two bolts per side, of 8mm diameter.
The bolt types to be used are not specified in the VSB 5B but the CAMS motorsport Schedule C.8 states that a minimum of high tensile grade "8.8" bolts are to be used.
End of Standards guff.
My design was overengineered but I am comfortable with this since I don't stuff about with essential saftey items. The seats were positioned inward (away from the door) to achieve two things 1) Better lining the driver up with the slightly offset steering wheel 2) Stop the seats from hitting the rear map pockets when it's moved back on the sliding mechanism.
The height of the seats was positioned to allow the sliding mechanism to move over the top of the cross member if for some reason a short person (not me) drove the car and had to move the seat forward.
The sliding mechanism of the seats was removed and I made up some frames to hold them in place, and square.
The frame for the drivers seat. One side was angled to clear the exhaust tunnel. The seat is bolted to this frame by 4x M10 grade 8.8 high tensile bolts. The nuts are welded to the underside of the top part of the frame. The countersunk holes are for the locating pins that the Swift seats have.
The front of the frame was bolted to the cross member by 5x M8 bolts and I installed some rivnets into the cross member.
The seats in their final position
Unfortunately while making these frames I forgot that VSB 5B requires that the centre line of the bolts need to be aligned with the top or bottom of any corrugation and be complemented with a shaped backing plate underneath. I ended up with this
... so I decided to modify the floorpan to remove the sections of corrugations that were in the way.
Note the evidence of part of the messy welding job (not me) next to the new plate that was done to the shell when I got the rust removal work done. If only I had the Lincoln MIG before getting this work done
Once those pieces were welded in and holes drilled through them for the bolts, the seat mount frames were bolted in place with a 120mm x 50mm x 3mm reinforcing plate with 8mm nuts also welded in place - for adherence to the necessary standards.
_________________
-Alan
I blame my dad for my love of minis. I think I was conceived in the back seat of one
I also blame my Dad for me being 6' 1" - not really the optimum height for driving a Mini.