Author Topic: Stan's 78 mini restoration  (Read 61725 times)

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #350 on: December 29, 2017, 06:18:45 PM »
A little more progress today, dash is installed, wired up, oil pressure line connected, speedo cable connected. Speedo cable was giving me fits so I pulled it out of the car - I realized the ends were not fitting into their respective sockets both in the transmission and the speedo head, so I took a fine file to those square sections and dressed them out a bit - once that was done both ends fit perfectly. This has to be one of the easier speedo cables to reach on the transmission end - maybe because the Spicer joints are smaller? Dunno, but it wasn't too bad

Anyway, I also found out what's hanging up the shifter - turns out the reverse light switch wasn't adjusted, and had wound itself all the way in so it was blocking the shifter mechanism. Once I backed it out I could easily get all 4 gears, now I'll have to adjust it to get reverse to slot in properly, then at last I'll be done with the shifter!

Got the rest of the wiring harness hooked up under the dash and started testing things - no smoke yet!   :D

I now have lights, but I haven't found the flasher units yet to test the turn signals and 4-ways. The wiper motor works and parks, and even the dome light works - with the doors no less!

Next I'll get the fuel pump ground wire made and tested, button up the shifter once and for all, find the flasher relays and continue testing the electrics.
« Last Edit: December 29, 2017, 06:25:11 PM by MiniDave »
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #351 on: December 29, 2017, 10:10:30 PM »
Got the turn signals and flashers working too, I also got the turn signal self canceling to work....I also clamped up the axle boots and tightened the tie rod ends. So the front end is done now, still have to finish sorting out the shifter and the fuel pump.

Next up, put oil in and crank up oil pressure......

1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #352 on: January 01, 2018, 04:34:33 PM »
It's freakin cold out, but I warmed up the garage enough to do a few things - I got the ground cable for the fuel pump made and installed, put the shifter together, put oil in the engine - man it takes a long time for 20W50 to drain down out of the valve cover when it's this cold and the oil has been sitting on the floor!

I got the distributor in and the base timing set - so it should at least start. Then I pulled the plugs and cranked up oil pressure.

About the only thing left to do to get it to start is connect the hot side of the fuel pump to the fuse panel, wire up the distributor and put some gas in the tank and see what she does!

I also need to adjust the rear brakes and bleed them along with the clutch before I can set it down on it's wheels and get to move itself.
« Last Edit: January 01, 2018, 04:58:43 PM by MiniDave »
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #353 on: January 05, 2018, 11:44:16 AM »
Today Dan drove up from Tulsa to my shop in KC to do the headliner install and front and rear windshields. I knew a headliner was a fiddly job, but man! When it comes time to do mine I'll either have Dan do it or the local upholstery shop.....I just don't have the patience.....

 
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline BruceK

Re: Stan's 78 mini restoration
« Reply #354 on: January 05, 2018, 01:39:15 PM »
And to me the simpler Mk. I and Mk. II style of headliner looks so much better than the later fussy to install style.
1988 Austin Mini
2002 MINI Cooper S
2007 Triumph Bonneville

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #355 on: January 05, 2018, 03:29:10 PM »
All righty then, headliner is done, and the front and rear windshields are in - took about 5 hours of steady hard work but I think the results are worth it!

It's supposed to warm up some tomorrow so I can open the garage door - tomorrow we'll see if she can make some noise!
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Online 94touring

Re: Stan's 78 mini restoration
« Reply #356 on: January 05, 2018, 06:15:13 PM »
The car is coming together nicely.  Too bad I couldn't be there on the initial fire up.

Offline BruceK

Re: Stan's 78 mini restoration
« Reply #357 on: January 05, 2018, 07:13:47 PM »
That headliner install looks fantastic.   It really looks like a jewel of a car.   Very clean and sorted.
1988 Austin Mini
2002 MINI Cooper S
2007 Triumph Bonneville

Online 94touring

Re: Stan's 78 mini restoration
« Reply #358 on: January 05, 2018, 07:16:08 PM »
Thanks. I'd say it's very wrinkle free too.

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #359 on: January 06, 2018, 07:24:31 AM »
Interesting the difference in color in the two photographs - mine and Dan's - between our two cellphones.
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline BruceK

Re: Stan's 78 mini restoration
« Reply #360 on: January 06, 2018, 08:59:22 AM »
Thanks. I'd say it's very wrinkle free too.

Yes. I jealously noticed that.  ;D    Better than the factory did it for sure.
1988 Austin Mini
2002 MINI Cooper S
2007 Triumph Bonneville

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #361 on: January 06, 2018, 09:43:45 AM »
Dan and I were wondering how they got it done quickly on the assembly line back in the day.......
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Online 94touring

Re: Stan's 78 mini restoration
« Reply #362 on: January 06, 2018, 10:29:47 AM »
That photo was enhanced, here's the original.   And another angle to the headliner.

Other things to note: original bows are stiffer and easier to work with. The new ones Stan bought were a bit flimsy and also a hair shorter. Not short enough to matter but I noticed. 
« Last Edit: January 06, 2018, 10:49:08 AM by 94touring »

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #363 on: January 06, 2018, 03:32:33 PM »
I guess I'm going to have to drop the shifter assy back out, I cannot get the reverse switch adjusted correctly and I can't tell what's wrong with it in the car.....I can't get this car into reverse.
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline jeff10049

Re: Stan's 78 mini restoration
« Reply #364 on: January 07, 2018, 01:32:33 PM »
the car is looking great I like the color. What type of trans is it? Could it just need to be run some to get some fresh oil on everything internal?

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #365 on: January 07, 2018, 01:54:43 PM »
It's your basic rod change gearbox, it was assembled when I got the car.....I have oil in the crankcase and I have cranked up oil pressure, so the gears have been spun quite a bit. The lever absolutely doesn't want to move back after you lift it up over the detent, the forward gears feel normal enough.....I'm hoping there's just something amiss in the linkage.....although it's pretty simple.....
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline stan360

Re: Stan's 78 mini restoration
« Reply #366 on: January 07, 2018, 07:41:17 PM »
Dave, i have the slightly shorter steady rod for 998, do you think this 1/2 inch  shorter rod would help this ? The rod on it i am thinking is the later one ?
« Last Edit: January 07, 2018, 07:44:49 PM by stan360 »

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #367 on: January 07, 2018, 07:44:19 PM »
It's possible that's exactly what's bothering it.......it could be that it can't get 4th or reverse because it can't move it far enough because that rod is just that much too long.....I'm still going to pull the shifter assy out and see about the adjustment of the reverse switch.

I'll go online and see what it says about those steady rods.....

Edit:yep - that could be the answer!
« Last Edit: January 07, 2018, 07:49:11 PM by MiniDave »
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Online 94touring

Re: Stan's 78 mini restoration
« Reply #368 on: January 07, 2018, 07:50:35 PM »
When my rod (giggity) was altered due to being loose, it would do precisely as you have described Dave.  Didn't know 998s had a short one.  Bet that's it.

Offline stan360

Re: Stan's 78 mini restoration
« Reply #369 on: January 07, 2018, 07:54:33 PM »
Ok, i will be back in a couple days , and can bring it down to you. I remember buying the shorter one after i got the shifter assembly, because like many other parts i acquired, i had no idea what would be correct so i ended up buying some xtras
« Last Edit: January 07, 2018, 08:00:35 PM by stan360 »

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #370 on: January 09, 2018, 01:34:47 PM »
The steady rod in Stan's shifter now is 18 1/2" from the center of the eye to the flat that butts up against the shift housing - anyone have one from a 998 that you can measure for comparison?

I also found the end of the reverse light switch bent over from moving the shift rod when things weren't put together correctly, but I was able to straighten it and upon testing it with my ohm meter it seems to work fine, so I put it back in in what I think will be the right location and adjustment.

While we're on the subject of shifters, anyone use one of those spring bias devices successfully? One of my friends had one on his car and it was constantly breaking the rubber bobbins at the back of the shift housing and causing him grief. He took it off, put in a new front bushing and two new bobbins and the car shifts perfectly now, and he hasn't broken anything in a few months now......conclusion, the spring adds too much torque and tears the rubbers.....do not use. It might be fine for a race car with a solid mounted shifter but not for street driven cars.
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline MiniDave

Re: Stan's 78 mini restoration
« Reply #371 on: January 11, 2018, 05:53:41 PM »
It's. A. Live!



I forgot to hook up the battery......

Yesterday it was 51*, today it's 14*......Stan came to bring me the missing shifter part tonight and I had him start it too, but we only ran it for a moment as it's just too cold to open the garage door.

Left to do.....

Bleed the brakes
Bleed the clutch
Install the shifter
Install and wire the horns
Install and wire the driving lights
I'm sure there's more......
Send it home.
« Last Edit: January 11, 2018, 06:02:58 PM by MiniDave »
1989 Cooper Racing Green
2009 Clubman S
1969 Jaguar XK-E FHC
2004 Audi Allroad 2.7 TT

Offline joakwin

Re: Stan's 78 mini restoration
« Reply #372 on: January 11, 2018, 05:59:38 PM »
sweet it runs
D16z6 Automatic, 4 wheel disc brakes, deseamed shell

Offline gr8kornholio

Re: Stan's 78 mini restoration
« Reply #373 on: January 11, 2018, 07:52:16 PM »
So is it just typical of these motors to have a slight run on after the ignition is turned off?  Sounded like this one did it, and mine does too.
I am the GR8KORNHOLIO! Are you threatening me?

Saussie Aussie 1965 Australian MK1 Mini.
"Beavis" - 07 MY/MY MCS, B/MY Konig Daylites, JCW sideskirts, TSW springs, TSW lower rear control arms -- Exploring the country with new friends since 11/09.

Offline BruceK

Re: Stan's 78 mini restoration
« Reply #374 on: January 11, 2018, 08:08:06 PM »
Success!!! 

I love the smell of a newly rebuilt motor as the new headers heat up and burn off whatever got on them and the paint on the block cures.  Technically it is not great smell at all - but itís all about lots of memories each time I smell it.
« Last Edit: January 11, 2018, 08:10:47 PM by BruceK »
1988 Austin Mini
2002 MINI Cooper S
2007 Triumph Bonneville