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Home > Show Us Yours! > '77 Clubman rebuild

robert

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uranus

very smart .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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608 Posts
Member #: 1106
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Hungerford, Berks




On 16th Sep, 2023 shane said:
Love this build.
the last 10% takes 90% of the time.
Keep chipping away Graham.

Shane


I think I am at the last 3% now and that is taking 99% of the time of the 90% time from the last 10%.


Just finished mopping it all out and carrying out some minor paint work repairs, so "Keep chipping away Graham." is not what I want to hear...





On 17th Sep, 2023 robert said:
very smart .


Cheers Robert, and Much lighter too.
Not got it weighed yet, but the "coupe" was 850 kg - so whatever happens this will be much lighter and so just a little quicker on acceleration.



3 days off work now, so I should be pretty much done by the end of the coming Weekend, barring the rear bumper being made from Carbon fiber - which will probably be next spring now.
In the meantime I have another Bumper to clean up and spray with some black paint, just to get it to a point I feel happy driving it on the road.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


robert

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uranus

You'll really notice that lighter weight , when i put the ally doors on the spud, i can stay in fourth gear a lot more .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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608 Posts
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Hungerford, Berks

Good news: Almost there.

Bad news: ALMOST there

As normal, I was overly optimistic with what I could get completed in 5 days - especially as there were a few parts I forgot to order and so had to wait for them to come.












However, just a few small things left to finish now.

I hate the stainless steel button head bolts on the grill, so they will be replaced with some black anodised bolts.
The grill has to come off again anyway to set up the headlights, so not really a problem.

Set up the headlights
Replace the nuts on the wiper wheel boxes with some that I have got painted up.

Get the cutting paste out from between the front panel and wings.
Polish the whole thing
Get the rear bumper sorted out and mounted.
Set up the washer jets for the front windscreen.

Ride height is set all around.
Rear toe and camber is set.
Front tracking is set dead ahead for now. but the caster and camber now setting on the front, then check ride height, toe etc.

I deliberately left this until the very last, so that I am not driving it around without finishing it, because I know me, and me would forget all the little bits once it is on the road.


It is road legal now: insured, "taxed" and obviously it is MOT exempt, so I am just itching to take it around the block.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


AlexB
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The boring bloke who runs this place.

Berkshire

It really looks cracking :)


e5tus

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428 Posts
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Dorset

Looking great. Well Done.

On 24th Sep, 2023 Graham T said:
I hate the stainless steel button head bolts on the grill, so they will be replaced with some black anodised bolts

Haha, sure this was already the plan months ago...
On 19th Jul, 2022 Graham T said:
On 19th Jul, 2022 e5tus said:

Yes to the black anodised fasteners, but you already knew that!
I have to admit I was swaying that way despite the massive costs involved - But I just wanted to see if anyone was awake out there *smiley*


robert

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uranus

weighbridge !

(maybe paint ic black )

looks brand new graham .*smiley*

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


Graham T

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608 Posts
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Hungerford, Berks

On 24th Sep, 2023 AlexB said:
It really looks cracking :)


Thanks Alex.


On 24th Sep, 2023 e5tus said:
Looking great. Well Done.
On 24th Sep, 2023 Graham T said:
I hate the stainless steel button head bolts on the grill, so they will be replaced with some black anodised bolts

Haha, sure this was already the plan months ago...
On 19th Jul, 2022 Graham T said:
On 19th Jul, 2022 e5tus said:

Yes to the black anodised fasteners, but you already knew that!
I have to admit I was swaying that way despite the massive costs involved - But I just wanted to see if anyone was awake out there *smiley*


Cheers.
yeah, it was the plan, I think it just got added to the list of forgotten stuff.
New bolts on order, should be here tomorrow.


On 25th Sep, 2023 robert said:
weighbridge !


Yes, That is the plan once I'm out and about with it.

On 25th Sep, 2023 robert said:


(maybe paint ic black )

looks brand new graham .*smiley*


I must admit, I also had the same thought - It does stand out a little behind the grill.
(List then gets longer again...)

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Jimster
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455bhp per ton
12 sec 1/4 mile road legal mini

Sunny Bridgend, South Wales

its looking great, well done!! How far did you get with the VNT turbo?

Team www.sheepspeed.com Racing

On 15th May, 2009 TurboDave said:

I think the welsh one has it right!


1st to provide running proof
of turbo twinkie in a car and first to
run a 1/4 in one!!

Is your data backed up?? directbackup.net one extra month free for all Turbo minis members, PM me for detials


Graham T

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608 Posts
Member #: 1106
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Hungerford, Berks




On 28th Sep, 2023 Jimster said:
its looking great, well done!! How far did you get with the VNT turbo?


Cheers Jim.

I got as far as taking the turbo out of the box, offering it up in the engines bay, scratching my head for a few minutes, then replacing it in the box.

it was too much work to change the exhaust manifold and "downpipe" for the model of turbo I bought.

It will be a spring project to find something a little more suitable to reduce the amount of work to do.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Graham T

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608 Posts
Member #: 1106
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Hungerford, Berks

Finally, after another 5 months off the project, I picked it back up on Easter weekend and I think it is now all but complete.
Well as complete as these things ever get...

Originally, really did not want to put wheel arches on it, but the front wheels were just too far outside the body, hence another addition to the finishing list.

I bought some cheap "group 2" narrow arches, knowing they would need a certain amount of "fettling" to get them to fit.
I actually ended up buying 2 sets, because to did not like how high up the front panel the front arches ended - Hence I modified a pair of the rear arches for the front.




























The next big decision was colour.
Should I paint them body colour or go for matte black?

Lets make it even more difficult to keep clean and go with Matte Black...







Today was its first outing. We had a local show about 300meters up the road from me, so that was a nice gentle run up the road.

































I now have a small list of snags/ changes to make.

1) Fuel leak on the fuel rail - just a weep, but something that needs dealing with before I take it out for a longer run.

2) Brakes - last October I had a weep on the offside front Caliper "link pipe" to lower chamber, which I thought was sorted. On the way back from the show the peddle went soft, so I assume its weeping again.

3) Gear stick - it really needs a nicer looking gaiter and some sort of surround to hide the mess I made of cutting the carpet.

4) I need to revisit the dash - The cut out sections for the switches and the access panel to the fuses on the passenger side look crap. I need to come up with a better way of finishing them.

5) clean the phone camera lens.


Anyhow, apart from it being a very short drive and a gloomy day, it was nice to get out and about in a Mini again.

Edited by Graham T on 6th May, 2024.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


Graham T

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608 Posts
Member #: 1106
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Hungerford, Berks

Just for fun:

since we got the car back in 1990:

It's had 6 Engine changes with 5 engines
998 - me wanting more power forced change
1275 - Think I broke a piston ring which forced engine change
998 - gearbox failure forced change - My original Engine
998 - gearbox failure forced change
998 - This was the Engine I first fuel injected and is about to be rebuilt to go in the coupe
1310 Turbo

3 full rebuilds - 2 budget and 1 extensive...
1990 - 1992 (roughly 2 1/2 years)
1999 - 2001 (roughly 2 years)
2019 - 2024 (4 1/2 years)


1990
I have not got any photo's of the car in one piece, as it was when we bought it. but this is the original colour and condition:



And one photo of it after respray, before being finished.






1992








2006








2024


Edited by Graham T on 6th May, 2024.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675


minimole23

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Wiltshire

Great work

On 7th Oct, 2010 5haneJ said:
yeah I gave it all a good prodding


shane

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2623 Posts
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Lowestoft, Suffolk.

Some great work there Graham.
Shane


robert

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6744 Posts
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uranus

looks v menacing in a good way .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM


AlexB
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6266 Posts
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The boring bloke who runs this place.

Berkshire

Awesome effort - she looks spot on imo


Graham T

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608 Posts
Member #: 1106
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Hungerford, Berks

Thanks all - I appreciate the feedback.


"looks v menacing..."

yep - I can already hear the shouts of "Oh god here comes that menace again".
But I will catch them out, 'cause it's now green with a noisy gearbox and exhaust, rather than blue.

🙂


The fuel leak on injector rail is now sorted and we found a weep on the nearside front brake caliper which is also hopefully dealt with.


So next step is a decent length run to settle everything then go back over all the suspension and whatever else comes up.

’77 Clubman build thread
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=618189

Siamese 5 port EFI testing
http://www.turbominis.co.uk/forums/index.php?p=vt&tid=611675

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