Restoration-Mini

Technical Forums => Maintenance and Modifications => Topic started by: MPlayle on March 26, 2022, 04:39:44 PM

Title: Blue 1983 "Window" Van
Post by: MPlayle on March 26, 2022, 04:39:44 PM
I figured it was past due moving the updates on the Van to its own thread in the "Maint & Mods" grouping.

I've been making progress on the "to-do" list for it.

Got the several parts orders in this week and last, so got busy with tasks.  I replaced the seat belts with new retractable ones and upgraded the horn to dual horns on a relay.  In the process of upgrading the horns, I also converted the front to a MK-1 style removable grill.

I replaced the old black door cards and fillet panels with new ones in Dove Grey.  I also redid the dash with matching pieces.  Before installing the new dash cover pieces, I replaced the old dash switches and made coroplast dash tray liners for better support over the painted cut/torn cardboard that it came with.  I also added a tachometer in front of the driver. 

I also have the supplies to make some custom side panels for the rear area that will match the door cards and dash.

I have the supplies to refurbish the seats - both need new foam on the seat bottoms, the driver's seat (LHD) bottom cover is torn at the rear seem where it meets the seat back.  I have new base foam and covers to put on.

There is also a new "dual function" accessory added - subtle clues in a couple of the dash pictures below.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on March 26, 2022, 04:58:10 PM
I mounted a similar 12V socket/USB charger in my green Mini, the only thing I might have done differently is that by being horizontal like that the plugs sometimes vibrate out especially on bumpy roads.

It's coming along nicely! I like the tach - did you do that or did it come with?
Title: Re: Blue 1983 "Window" Van
Post by: 94touring on March 26, 2022, 05:57:04 PM
I have my tach in the same spot.  Handy feature!
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on March 26, 2022, 07:31:04 PM
The power port is kind of a necessity.  The speedometer is in kph, so I use my Garmin GPS as a mph speedometer and the power port lets me run it on constant power versus the internal battery that is now about 12 years old.

BTW, the power port is not the "subtle" accessory.  Clues are on the lower dash rail.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on March 26, 2022, 08:03:07 PM
I saw the buttons on the ends of the dash rails, some kind of switch?

Like I said, I have power ports in my cars for the same reason, I'm just saying the cord comes loose and loses the connection on bumps, so next time I'll put it at an angle somehow - or vertical.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on March 26, 2022, 09:19:17 PM
Quote from: MiniDave on March 26, 2022, 08:03:07 PM
I saw the buttons on the ends of the dash rails, some kind of switch?

Yep.  Dual level seat warmers!  The wiring is all set and tucked away waiting on my redoing the seats.  Since I have to recover the seats anyway, I thought I would give it a try adding them on both sides.

I have used the same model power port on several Minis now and not had any issues with the power adapter coming out nor a USB connector coming loose.

Title: Re: Blue 1983 "Window" Van
Post by: cstudep on March 26, 2022, 09:24:56 PM
I was just typing up seat warmers? and it warned me I wasn't  posting to the latest message so I backed out to see what was posted since I started typing.

I didn't figure there was much need for such a feature in Texas but couldn't think of much else it could be while mentioning also working on the seats. Power seats or power windows seemed even less likely than seat warmers so that was going to be my guess
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on March 26, 2022, 09:39:33 PM
True, there is not a lot of need for seat warmers in South Texas, but they do add some extra comfort to the usual "barely adequate" factory heater.  Plus it is not something often found added to a classic Mini.

The kit was about $50 through Amazon. 

Title: Re: Blue 1983 "Window" Van
Post by: Tim on March 28, 2022, 04:13:55 PM
Which kit do you get for the seat warmers?  I was looking into them yesterday for my Ausi Moke Seats.  I have new covers on the way and wanted the heaters for those chilly mornings and evenings.  Not much a heater can do in an open air Moke!

Tim
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on March 28, 2022, 05:54:22 PM
I ordered this kit through Amazon:

https://www.amazon.com/dp/B08YD3WJ11?psc=1&ref=ppx_yo2_dt_b_product_details (https://www.amazon.com/dp/B08YD3WJ11?psc=1&ref=ppx_yo2_dt_b_product_details)

Title: Re: Blue 1983 "Window" Van
Post by: Tim on March 30, 2022, 05:14:34 AM
Great.  Thanks for the link.

Tim.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on March 30, 2022, 10:55:57 AM
If you get the kit and want a few installation tips, let me know.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on April 04, 2022, 03:04:04 PM
Some more progress - finished the rear cargo area.  Custom made the side panels, painted some plastic wall corner guards for using as finishing strips to cover the 'c' channel structural supports under the rear windows, and custom made a matching cover over the fuel filler neck.

Next up is reupholstering the seats with the heaters added (new base foams and covers for both seats).

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on April 06, 2022, 07:55:30 PM
Got the driver's seat finished and reinstalled in the car.  Here is a picture of the seat finished before putting it back into the car.  I am going to pause a few days before doing the passenger seat.  I needed to order a few more of the clips that hold the fabric around the base of the frame.

I ordered the clips from 7Ent as that was the only item I needed.  They were $12.50 (plus shipping - total $20.97) for 20 clips at 7Ent versus $26.50 (plus shipping) for the same 20 clips from Mini Mania.  Ordering from Mini Spares would have been about $6.50, but the shipping would have made it about the same as from 7Ent.



Title: Re: Blue 1983 "Window" Van
Post by: BruceK on April 07, 2022, 02:00:10 PM
You do good upholstery work!   Looks factory.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on April 11, 2022, 01:04:51 PM
Finished redoing the passenger seat today.  I just have to put it back into the car.

I did not take a picture as it looks just like the other one.

I did discover over the weekend that I need to replace the driver's side outer door handle.  The key I have does go in and turn the tumbler, but the handle does not lock.  Also, if I turn the tumbler only half way and tug (even gently) on it the whole tumbler unit comes out of the handle.

Ordered a replacement from Mini Spares.  I should be here by the end of the week.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 05, 2022, 11:01:14 AM
I have been enjoying the Van now for a bit (alternating between it and the green Mini 35).

I have confirmed it has the pre-1984 transmission grearing with a 3.64 final drive.  It does about 62mph at 4K RPM.  That tends to make things a bit harsh when having to do highway driving or much distance driving where 65mph (or more) becomes necessary.

I have been waffling between:
a) Moving along one of the two Minis I have and chasing down another Moke.
(If the green Mini 35 should sell, I may chase a Moke and upgrade the Van.  If the Van should sell, then keep the Mini 35 and chase a Moke.)
b) Keeping both and just spending more than I could ever get back to customize the Van into a more highway and hot weather friendly car (engine upgrades to the existing 998 or replacing with a tuned 1275, adding "custom" A/C).

I can't go for 3 Minis (as much as I would like to consider it) as I live in an apartment.  I have 2 detached 1-car garages added to my lease for my current Minis.  They don't have room in either one to "double up".  The rises in the local housing market have basically priced me out of buying a house as well.

I am open to thoughts and opinions for discussion.
Title: Re: Blue 1983 "Window" Van
Post by: Brit_in_TX on June 06, 2022, 07:18:14 AM
Could you not rent an off site storage for one of the three minis and rotate them between there and your home garage(s)? 

Or is there an option to rent a larger space and have all 3 minis away from your apartment, you would then save the money on the garages you lease in your apartment complex?
Title: Re: Blue 1983 "Window" Van
Post by: jeff10049 on June 24, 2022, 12:00:59 AM
Nice work, I like the idea of upgrading the van or having a van and moke just my thoughts.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 24, 2022, 06:51:14 AM
jeff10049,

That is the way I seem to be leaning at the moment.  My green Mini Saloon (Mini Cooper 35 with backdated MK-I exterior appearance) is likely the easier to sell over the Van.

I bought a borescope at Habor Freight to peek inside the 998 and try to glimps the condition of the cylinders.  I need to do that and a compression test to help decide what engine upgrade path to take.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 27, 2022, 05:00:11 PM
Okay, so I got out to the garage this afternoon (after a cool front and some rain storms blew through to reduce the heat) and took a look into the 998 in the Van.

Decoding the engine number (along with measuring speed/RPM with the new tach and GPS) indicates:
- Engine size is 998
- Version is A+
- Head is already "unleaded"
- Standard ratio gearbox
- 3.647 final drive for Vans
- Dished pistons with press fit wrist pins

Compression test results:
#1 = 157
#2 = 155
#3 = 155
#4 = 155

My guess from this information is it is likely the regular "8.3:1" compression engine and not the higher "10.3:1".

I was not able to get any pictures of the screen on the borescope as I looked into each cylinder.
All 4 cylinders looked much the same: original honing cross-hatch still visible, mild carbon present but not fully covering the piston tops, some marking notable on the piston surfaces, but not really readable, good burn color on all spark plugs - no differences between any of the plugs.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on June 27, 2022, 05:14:53 PM
So, it's a nice 998 A+?

I think the only thing to do is either just run it, or replace it with a 1275. And if you're going to build a 1275  engine, might as well build a good one with ported head, 10.3-1 pistons and a good cam and rockers.

I think I really like the 3:1 diff ratio I put in the Inno, but the 2:76 in the green car is really nice on the highway - 3400 @75 mph! So as long as you have the torque, either one of these is a good way to go with the bigger motor.

I think you could run a 3:44 in the 998 gearbox and it would still pull nicely, since the Vans were lighter than the sedans and wagons? (I have an extra I would make you a good deal on if you decide to go this way.)
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on June 27, 2022, 07:28:34 PM
That is one of the most consistent compression tests I have ever seen across all four cylinders.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 27, 2022, 07:46:00 PM
Dave,

Actually I was considering "hopping up" the existing 998.  I have been starting to compare pricing between getting a 1275 and working up the existing 998.

Getting a built up 1275 will run me about $10K+, whereas building up the existing 998 will likely run about $3K to $4K doing the work myself.

The existing 998 already has an alloy intake and LCB exhaust.  I was considering keeping the bottom end "as-is" and replacing the cam (either Kent 266 or Mini Spares EVO-1), changing to a "stage-3" head with 1.4:1 rockers, and going to a 3.1 final drive.

I would be able to reuse most of the ancillaries on the current engine if I upgrade it versus having to replace them if going to a 1275 (distributor, intake, exhaust, flywheel & clutch assembly, carb, etc.).
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 29, 2022, 07:07:22 AM
Still doing a bunch of research on how to achieve what I would like, but it is looking like I can accomplish it with a decent "Stage-2" kit (or equivalent).

Title: Re: Blue 1983 "Window" Van
Post by: BruceK on June 29, 2022, 04:22:03 PM
So just an improved head and carburetion? 
Title: Re: Blue 1983 "Window" Van
Post by: 94touring on June 29, 2022, 05:19:27 PM
Toss in a 1098 crank. That's easy (almost) free power.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on June 29, 2022, 07:32:31 PM
I am trying to avoid completely tearing the engine apart and also trying to keep to a reasonable budget.  I have been going through several threads on the Mini Forum and a bunch of Calver's articles.  The goal is to improve the road driving of the car - not really make a hot-rod out of it.

It already has an alloy intake and proper LCB exhaust, so changing the head and rockers, and air filter I will have the same as in the typical "Stage-2" kit.  The HS-4 carb already on it will be just fine with a possible needle change.

That should bring it up to close to a base pre-A+ 1275 which wouldgive me the extra oomph to support changing to a 3.1 final drive.  Changing the final drive won't require a complete tear down either - just pulling off the differential and speedo drive cover.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on August 23, 2022, 03:19:52 PM
All the parts I ordered for the engine "upgrade" effort have arrived and I began some of the teardown yesterday and today.

I have the oil and coolant drained.  I have the hubs and axels out for pulling the engine.  I have the carb and intake pulled.  The alternator is removed along with the coil/dizzy cap/rotor/wires/plugs/horns/starter.  I have the wiring tucked out of the way and the oil pressure line disconnected and out of the way.

Next up is getting the LCB exhaust out of the way, the shifter disconnected, the clutch slave cylinder out of the way and various hoses out of the way in order to then loosen the motor mounts and pull the engine.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on August 26, 2022, 11:02:21 AM
Smallish progress today, but where I wanted to be by the end of this week: the engine is out and on the bench for inspection/cleanup before undertaking the upgrades.

I need to order some new motor mounts - one fell apart as I lifted the engineout of the car.   :(

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 07, 2022, 12:05:57 PM
Some more progress on the engine upgrade project.

First = where I started today:
While waiting on the additional bits to arrive (got here yesterday), I had disassembled the differential to swap the crown gear, removed the speedometer drive housing, swapped the pinion gear and speedometer drive gears, reinstalled the speedometer drive housing, cleaned and painted the radiator shroud, mounted the new alloy radiator in the shroud, and started preparing some of the new heater/cooling system hoses.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 07, 2022, 12:10:30 PM
Second = where I finished today:

The differential is reassembled and back on the transmission, the pot-joint shells have been cleaned and reintalled, the old head off the block, The old rocker arms assembly removed for swapping springs and spacers to the new assembly, started preparing the new rocker arm assembly, and started preparing the new head.

I also removed the mechanical fuel pump and installed a blanking plate as I am going to change over to an electric fuel pump.


Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 07, 2022, 12:25:28 PM
 :-[   And wouldn't you know it, ... after posting the progress I realized I forgot to bend over the new lock-tabs on the crown gear bolts in the differential.  I get to pull the differential back off and take it apart enough to set the lock tabs and put it back together.   :-[

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 07, 2022, 02:12:46 PM
What did you use to pull the bearing off the carrier?

Gaskets will be on the way as soon as you get me the shipping cost....
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 07, 2022, 02:58:03 PM
Dave,
I have a set of bearing pullers that fit under the bearing and lifted it off intact.

I sent a direct email with the shipping cost of the speedometer and the tracking information.

Thanks!
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on September 08, 2022, 10:17:47 AM
Looks like it will be ready for Cars & Coffee this Saturday?  ;D

Nice progress!
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 08, 2022, 11:43:58 AM
Quote from: BruceK on September 08, 2022, 10:17:47 AM
Looks like it will be ready for Cars & Coffee this Saturday?  ;D

Hardly!

Yesterday felt like a "2 steps forward, 1 step backward" day with the "oops" on the differential crown gear lock-tabs.  Fortunately, Dave has the gaskets I need and I had the speedometer he needs for Clancy's Moke.  I get to redo the differential next week.  Meanwhile, I will try to finish up the head this weekend so I can put the engine back up on the bench to do the diff.

I'm thinking even considering the TXABCD in Round Rock Sept 23-25 may be overly optimistic.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 08, 2022, 04:44:47 PM
Yeah, diff gaskets probably won't make it till Sat at the earliest.....they went out with this morning's mail, but the post office no longer operates at anything resembling speed.

I'm now wondering about the big parts order I placed with spares today - if it will be delayed due to the days of mourning over the Queen's passing?

I also wonder if Charles will be "King for a Day" and then abdicate in favor of William or if he'll wear the crown for a while? He's 73 already, I think it's time for some of us old farts to let those with say more flexible thinking take the reins, and we just act in an advisory role - if asked.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 08, 2022, 05:08:08 PM
Hi Dave,

I am not really expecting the gaskets to arrive until Monday, so no problems there.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 09, 2022, 03:50:14 PM
Steady progess today:

I got the new rocker arm assembly done up, the new head installed (including a new water pump bypass hose), the rocker assembly installed on the head, and a preliminary valve adjustment done.

I did the valves in the "Ed China" style: find TDC for the compression stroke of each cylinder in the firing order and set that cylinder's valves, then move to the next cylinder in the order.

I then put the engine back up on the bench and removed the differential again to recheck the crown gear bolt torque and tap over the lock tabs.  I cleaned all of the gasket surfaces ready for the new gaskets Dave sent to arrive for reassembly once again.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 09, 2022, 04:58:15 PM
You remembered the push rods then?   77.gif
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 09, 2022, 06:14:28 PM
Quote from: MiniDave on September 09, 2022, 04:58:15 PM
You remembered the push rods then?   77.gif

Yep.  I carefully numbered them in order when I removed them when pulling the old head: remove rocker arm assembly, remove push rods in order and inserted into a box lid with each labeled, remove the head.

Assembly was the reverse order: put the new head on the block (with the new bypass hose in place and a new head gasket), install the push rods in order, install the new rocker arm assembly, torque everything to proper specs, adjust the valves.

I plan on rechecking the head torque and valves again once the engine is back in the car before firing it up.


Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 17, 2022, 03:26:30 PM
Back to making some forward progress again today.

I got the new electric fuel pump wired up, the differential covers installed with new gaskets (thanks again to Dave for the gaskets), and the engine bolted back into the car on new motor mounts.

Next up is starting to put all the accessory bits back on (engine steadies, manifolds, carb, alternator, etc.), fill it with fluids, check for oil pressure, etc.

Anyone have suggestions for how to best bleed air out of the cooling/heating system?

I installed all new silicone hoses, including to the heater which also got flushed.  As such, there is currently no fluid even in the heater.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 17, 2022, 07:07:32 PM
I don't usually see any problems with air bubbles. I fill it up, run it a bit, then shut it off and top it up. Open the heater valve of course....
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on September 18, 2022, 08:05:07 AM
Yeah. That's all I've ever done. Fill it. Run it. Let it cool and top it off.  Repeat that at least once.

Think you might be able to go to the Texas ABCD?
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 18, 2022, 12:17:49 PM
If I go to TxABCD, it will be as a spectator only.

I don't expect to have it all back together by next weekend.  I know I will have at least a couple of days of work that will keep me away from the Mini this week.

I "should" have it back together and start running it in the following week.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 18, 2022, 12:23:25 PM
Still hot down there? Mid 90's her till mid next week....
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 18, 2022, 12:33:21 PM
Yep, still mid-to-upper 90s.

I am working in a small 1-car garage with basically little to no circulation, so I tend to last for about 3-4 hours of effort at a stretch.  At that point, I am sweat soked clear through and "melted".

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 23, 2022, 01:44:13 PM
Time for the next progress report:

It ... Is ... Alive! ... ... ... (sort of)   ::)

I cleaned the carb and changed the needle (from an AAU to an ABD), installed it, and got all the cables and hoses connected.

I relocated the hors and got them wired back in and working. 

I then crank tested the engine for oil pressure.  First try got no pressure, so I primed the oil pump (remove the banjo bolt for the feed line to the filter and trickle some oil back into the block).  Second try started building pressure after about 3-5 seconds and built to good pressure (60 psi cold).

I then power tested the new fuel pump and got fuel up to the newly installed inline filter at the carb.  I connected the fuel line to the carb, cleaned and installed the spark plugs.

I then set the choke and tried firing it up.  It started right up and ran smoothly.  I did need to raise the idle a little bit as it warmed up and I could take it off choke.  I let it run until fully warmed up, then shut it off for a few minutes.

I went to try a warm start and got nothing.  The fuel pump would come on, but when turning the key to the 'start' position, there would be nothing - no click(s), no cranking of the starter, nothing.  I tried tapping the starter and the solenoid with a small mallet - still nothing.  A few more tries of tapping things and the solenoid would seem to give a "half-hearted" attempt at a click, then back to nothing.

I hooked up a test light to the solenoid terminal where the signal wire from the ignition switch connects to confirm power getting to there and that apparent extra jiggling made the solenoid work as the engine fired right up when testing for power to the solenoid.

Time to order a replacement since the current one wants to be dodgy part of the time now.

I called it "done" for today.  It will be a few days before I can get back to working on it, at which time I will recheck the torque on the cylinder head studs.  I still need to clean and regrease the inner portion of the pot-joints and reinstall the axels, hubs, and wheels before I recheck the valve clearances.

With a little luck, it will hopefully be done next weekend.
Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 23, 2022, 02:26:51 PM
I think I have a spare new solenoid - it's the one on the fender, right?

Make sure you have a good ground connection between the block and body.
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on September 23, 2022, 04:00:52 PM
And don't totally rule out the possibility of a bad battery.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 23, 2022, 05:47:21 PM
Quote from: MiniDave on September 23, 2022, 02:26:51 PM
I think I have a spare new solenoid - it's the one on the fender, right?

Make sure you have a good ground connection between the block and body.

Yes, it is the 3-terminal style mounted on the inner fender.  I will check the grounding of the of the solenoid to the fender. 

I know the engine block to the body has a good ground: I reinstalled the original ground strap in the same manner as it was when I removed it and added a second ground strap from the flywheel housing to the fender (scraped the paint to bare metal under the strap mounting to the fender).

Quote from: BruceK on September 23, 2022, 04:00:52 PM
And don't totally rule out the possibility of a bad battery.

I have been keeping the battery on a tender, but will take it to the nearby Autozone and get it tested.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 26, 2022, 03:59:39 PM
Progress today:

Got the battery checked and it is okay.

I took the solenoid off the fender and found fully painted metal underneath (with a tiny bit of corrosion appearing), so the gounding was just the self-tapping screws mounting it to the fneder.

I took a wire-wheel to the fender and removed the paint to bare metal under the solenoid back plate to give it more grounding surface and remounted the solenoid.  I will test it tomorrow or Wednesday.

I also cleaned up the inner pot joints, replacing the boot on one and got the axels and hubs fully back in the car and the brake calipers remounted as well.  I put the front wheels back on and snugged them up ready for putting the car down off the jack stands.

Tomorrow or Wednesday will be the "off the stands", recheck the valve clearances, and retest the solenoid.  Then it will be reinstall the grill and bonnet, and test drive!

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 27, 2022, 11:46:42 AM
More "two steps forward, one step backward" action today.

Got it down off the stands, the valves rechecked, the front wheels torqued, and all ready for testing.

It fired right up on the first try.  I was running it on choke and warming it up and the sounds in the garage seemed a bit off.  Then it started sputtering and died.  The "sound of silence" had returned - this time the new electric fuel pump had quit.  It still cranks over, so the solenoid issue seems fixed for now.  Still thankful Dave had one to send me for a spare it case the current one acts up again.

I pulled the fuel pump to try to return it and order another.  The one that quit is an Edelbrock 17303 (30 GPH at 2-3.5 PSI).  I tried it because it was in stock.  I'll try to order a Mr. Gasket 42S as I had had good success with those.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 27, 2022, 12:12:06 PM
I returned three of those Mr. Gasket pumps to Oreily's before I got one that worked......good luck on that.

I like the idea of an electric pump, but I have a mechanical on my green car and it's never failed. The only advantage of these small electrics is that you can find them everywhere

It's funny......the one on Buzz used to quit working as I drove, give it a little tap and it would happily pump away - till it stopped again. I replaced it with the above problem pumps and finally got one to work. Since then the pump off of Buzz has been on my engine stand and it works perfectly!
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 27, 2022, 12:29:44 PM
Dave,

I still have the mechanical pump, although it would be a chore to put it back on the engine and plumb the hoses again.

I have not had issues with the 42S pumps I used in the past, though I have heard of others that did (like you).  This Edelbrock lasted maybe 10 minutes total time between Friday's startup and today's effort.

Title: Re: Blue 1983 "Window" Van
Post by: 94touring on September 27, 2022, 02:29:55 PM
I have both the 42s and Eddlebrock on the minis and bus.  I had an older 42s stop working on the bus and was replaced with the edlebrock.  Otherwise no failures to speak of.
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on September 27, 2022, 04:10:13 PM
Quote from: MiniDave on September 27, 2022, 12:12:06 PM


I like the idea of an electric pump, but I have a mechanical on my green car and it's never failed. The only advantage of these small electrics is that you can find them everywhere


Well, another advantage is that an electric pump can't develop a leaky diaphragm and let fuel run into the sump diluting the oil causing engine wear like a mechanical pump can do. Not sure how often that happens but it seems possible. 
Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 27, 2022, 05:37:04 PM
Possible, but seems unlikely......seems like if it gets a split that would let it leak into the sump, it wouldn't be able to develop any pressure?

I've had a couple fail on other cars, but never had one fill the sump with gas, the car just quit running.

YMMV
Title: Re: Blue 1983 "Window" Van
Post by: 94touring on September 27, 2022, 06:38:01 PM
Quote from: BruceK on September 27, 2022, 04:10:13 PM
Quote from: MiniDave on September 27, 2022, 12:12:06 PM


I like the idea of an electric pump, but I have a mechanical on my green car and it's never failed. The only advantage of these small electrics is that you can find them everywhere


Well, another advantage is that an electric pump can't develop a leaky diaphragm and let fuel run into the sump diluting the oil causing engine wear like a mechanical pump can do. Not sure how often that happens but it seems possible.

Rare but the vdub guys bring that up in fuel pump discussions.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on September 30, 2022, 01:11:01 PM
And the next wave of the saga hits.

Got the replacement fuel pump installed and plumbed in.  Turned the car on to hear if the new pump runs and heard it pull its prime and fill the line and carb.  Pulled the choke and the car fired right up.

Turned it off and installed the grill and bonnet.

Fired it back up to see about a quick run around the apartment parking lot, and ...

No clutch action!  Pedal has no resistance all the way to the floor and back up.

Set about bleeding the clutch system using my "mini-vac" bleeder kit.  Pulled lots of air and dirty fluid out.  Used up all the spare fluid I had on hand and need to get some more and continue bleeding the system.  I did get some clutch action back, but it is all low, near the floor.

I do have a replacement braided clutch line (for from the master all the way to the slave) and an extra slave I can try if more bleeding does not do the trick.

Edit:
I just did a quick check as the two slave cylinders I have are slightly different.  It turns out the one already on the car is a Verto slave on a pre-Verto clutch arm arrangement.  The spare I have is a pre-verto slave.  It looks like I will be changing it over to the spare and new line.

Title: Re: Blue 1983 "Window" Van
Post by: MiniDave on September 30, 2022, 03:56:19 PM
I find these clutches really easy to bleed, I put a hose off the bleeder into a small water bottle with an inch of fluid in the bottom, fill the master, go into the car and push the pedal down three times, close off the bleeder and she's done.

Once in a while I have to pump the pedal a few times quickly to get the fluid moving but that's about all it takes.

If you're getting lots of blackish fluid, that means the seals are failing in either the slave, master, rubber hose or all of the above. Changing the slave is smart...do that first always. If you need a master I have an order going in this weekend to Spares. I can easily add it in....
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on October 04, 2022, 02:03:48 PM
Had it out for its first "shake down" drive today.  Took it to fill the tank, then a car wash to clean it.  It ran well.  After washing it, I did a short drive further out from my apartment to run it up a bit and verify the results of the final drive change.

Seat of pants evealuation: acceleration performance is about the same as before, which I expected with the taller final drive offset by the performance boost of the performance head & rockers.  There were no apparent leaks or other issues.

When I pulled the old final drive out, it turned out to be a 3.44 gear set, but the calculated performance (per the Guessworks site) was as though it had a 3.64 set.  This leads me to conclude that I have non-standard drop gears. 

The result of the change to a 3.1 final drive gear set with the non-standard drop gears is as though it has a 3.2 final drive: 4K rpm = 70 mph.

I am happy with that.  Now to start enjoying it again.

Title: Re: Blue 1983 "Window" Van
Post by: BruceK on October 04, 2022, 05:33:53 PM
Success!   I'm sure it's great to have it back on the road.   are you going to C&C on Saturday?
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on October 04, 2022, 08:49:48 PM
Quote from: BruceK on October 04, 2022, 05:33:53 PM
Are you going to C&C on Saturday?

That is the plan if there will be other Minis going as well.  Meet at the usual place & time before the C&C?

Title: Re: Blue 1983 "Window" Van
Post by: BruceK on October 05, 2022, 12:35:03 PM
Yes. Let's meet up at 6:30 AM at Whataburger. Some people, such as Brad, are going to the British car show in Houston. Not sure how many.
Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on October 15, 2022, 10:45:19 AM
From some of my most recent posts, the solenoid issue had seemed to go away.  That was until Thursday.  I took the Mini Van out to go get lunch and do some errands.  Stopped one place and when I went to leave, ... nothing from the solenoid.  It had died for good apparently.

I was able to push start the car and get home.

This morning I changed out the old solenoid for the one I got from Dave and all seems right again.

Title: Re: Blue 1983 "Window" Van
Post by: MPlayle on October 29, 2022, 03:28:34 PM
Some validation that my work on the Mini Van has been worth it:

It took second place in its class (Classic Minis) out of 11 Minis present at the Boerne All British Car Day car show today!  A lot of people made comments of being impressed by it as well as comments about not seeing one like it before (meaning the Van version as there was a very nice 1980 Estate with a round-nose and VTEC conversion among the Minis present).

First place was Jim Davidson's 1966 Maroon MK-I Cooper-S and third was Tiffany Holt's blue VTEC Saloon (Super-Cooper conversion).
Title: Re: Blue 1983 "Window" Van
Post by: BruceK on October 30, 2022, 05:16:54 AM
CONGRATULATIONS!   4.gif
Title: Re: Blue 1983 "Window" Van
Post by: Brit_in_TX on October 31, 2022, 06:52:57 AM
Congrats Michael!  Wish I had been able to make it to Boerne for the show.