I'm finally getting off my butt and putting my mini back together. so far so good.

I cant seem to get the doors to align properly and now the bolt that holds it in has started to round off


also what is the best way to get new windscreen moulds on? the one I got seemed to be longer than I need. I cut one end so I can shape it better but I cant get it to sit flush around the rounded edges. Do I need to dunk it in hot water??

Normally just nip bolts up but not too tight, close door with bits of cardboard around edges to align. The tighten the bolts you can get to (under guard, inside door) Open door and tighten others, should be pretty much spot on.

You need the special little tool to put moulds in after the screens fitted. Best done on warm/hot day and with two bottles of liquid, one a spray bottle with soapy water, the other filled with cold beer.

Step 1. replace rounded head bolts with better ones...
Step 2. do what PeterB says above...

EDIT: windscreen rubbers benefit from laying in the sun for a while before fitting...

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"Show me the Mini!"

Note the top bolt inside the door should have both an angle cut aluminium washer, and a flat washer. If not, it will distort the door skin when tightened.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.