Restoration-Mini

Technical Forums => Restorations => Daves Garage => Topic started by: MiniDave on January 03, 2015, 01:51:07 PM

Title: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 01:51:07 PM
I had a '62 Cooper S back in the day and wanted another classic, but prices for good cars are hard to swallow these days and non rusty cars are even harder to find. When I chanced on this Clubman Estate on Mini Mania I emailed the owner and made arrangements to fly in to Baltimore to see it.

I liked it well enough to buy it, and to the owner's surprise decided to drive it back to KC. I hadn't brought any tools, fluids, parts or anything, just me and a well stocked credit card - something I would need when I got home but fortunately not on the trip. On the first days drive I stopped in Columbus Ohio as I had MINI contacts and friends there. The next morning I made a few adjustments to the valves and carb and headed home, making it in one straight drive.

If you ever want to learn about a car you just bought, a cross country drive will sure tell you what you bought - my car came with stacks of paperwork including MOTs and rec't for work done over the years, including an engine overhaul done 5K miles before. However, I realized early on in the drive that things might not be quite up to snuff as the engine just didn't seem to have the power it should, leaked oil like crazy and the entire car rattled, buzzed and carried on unbelievaby. So, I had a lot of time on the drive home to start making plans for improvements. I'd been looking for a car that had a good body, I knew I could do any mechanical work needed....

So: Plans......

1) the paperwork indicated that it did not have unleaded seats, so I put an additive in the tank on the drive home, but I would pull the head and have hardened seats and a valve job done - couple hundred bux, right?

2) fix the oil leaks

3) clean and paint under the hood a bit

4) I also needed to replace the right drive sealed beams with some left drive ones for our roads.

Oh, and fix all the rattles, buzzes squeaks and the miserable driver' s seat that was killing my back on the drive home.

Total budget, maybe $500 right? Riiiiiiggggghhthhttttt.......... ::)

I decided the easiest way to proceed would be to drop the engine and subframe out together, then I could easily clean and paint as well as find the oil leaks and fix them too.

So here's what I started with.....

(http://forums.kcminiclub.com/download/file.php?id=718)

Doesn't look too bad, does it? Here's what it looked like out of the car.....

(http://forums.kcminiclub.com/download/file.php?id=787)

The subframe was pretty manky tho.....

(http://forums.kcminiclub.com/download/file.php?id=781)

And the engine compartment that had been hidden by the engine was pretty rough looking too. Unlike Edd China I cannot abide putting dirty parts back in, so I made plans to get everything shipshape.

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 02:05:41 PM
The first thing once it was out of the car - off with it's head!

I took it apart, and that's when I got the first clue that what they consider an overhaul in ol Blighty might not be the same as what I do at least. For 5k miles, the cylinder head and valves were really carbonned up, and the "new" valves didn't match each other....

So I took it down to my favorite engine shop and told them to make it like new again.  They took it apart and found that not only did it need new seats, it also had no stem seals, worn out guides and in general needed a LOT of work - about $600 total including the new stellite faced exhaust valves, but it sure looked great when it came back!

Here's the before.....



And the after...



While I was waiting for the headwork to get done I took a look at the rest of the engine, the bores looked terrible, with rust embedded in the bores, like the engine had sat outside for a long time or something. I decided to tear it all down and go thru it. I found a few interesting things, a few good things and a lot of not so good things.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 02:21:09 PM
One of the first things I found was a brandy new looking duplex timing chain.....so it was clear someone had been inside it.....

The bores looked awful, and from the carbon buildup on top of the pistons it's clear where a lot of my oil had been going.

The rod bearings, main bearings and thrust washers looked almost new, but the piston markings showed the engine had been bored out 60 over already, there would be no further enlarging of this block, which meant I had a choice to make - sleeve it back to stock 1275 and buy new pistons, be-balance the whole engine, or find another block. I got lucky and found a Sprite block from a friend, and set about converting it to use in a Mini (more on that later) and boring it to 60 over so I could reuse my pistons.

With that in mind everything went down to the machine shop, where the block was boiled, align bored, the cylinders bored and finish honed and the top of the block skimmed. The crank had 10 under bearings indicating that the crank had been machined once already, but when we checked the journals we found they were tapered! We were able to save it at 20 under, so I began making a list of parts to order from Guido the Clown.

As a favor, the machine shop also hot tanked the subframe and it came back clean and ready to paint. I did a bit of straightening of places where the car had been lifted using the subframe and been bent and got it in a coat of primer.

So, another $800 of machine work including all the block work, crank work, hot tank, and a complete re-balance and I was ready to put it back together.....

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 02:36:38 PM
The Sprite block and Mini block are exactly the same with only a few differences that don't keep it from working in a Mini - however going the other way is not nearly so easy. The one big difference is of course that the Sprite is rear drive and has an oil pan instead of a gearbox under it, so the oil pickup is handled differently. The Sprite block is threaded for the oil pickup to mount to the block, where the Mini is simply flat with a hole bored in it. Here's are the two blocks side by side, the large hole on the top flange is where the oil pickup goes, the Sprite is on the left......

(http://forums.kcminiclub.com/download/file.php?id=820)

You don't have to do anything about it, but I decided to fill it in with some metal epoxy and drill it back straight to match the Mini bock. I also found the oil passage from the oil pump to the block was smaller on the Sprite block, so I drilled that out too.

I teach automotive courses at a local college, so I used the school's big ol drill press....


Here you can see the difference in the size of the oil port too, and the extra holes drilled in the back of the block for the seal mount - the Sprite block is on the left here and the large round indentation is where the oil pump goes. The oil galleys had been drilled and threaded on the Sprite block too, so all I had to do was locktite some plugs in there.

(http://forums.kcminiclub.com/download/file.php?id=824)

Once that was done I took a tap to all the threaded holes in the block and cleaned it thoroughly to get ready for a coat of paint. The later Minis are painted red rather than Morris green, so I went with red. The rear main seal is done differently on the Sprite too, but you simply remove that part to use it in a Mini, and I filled the holes with SS allen screws lock tighted in for security.

while I was in there.....I'd been convinced I needed a center mount oil pickup, and in order to install one of those you have to remove the layshaft in the transmission. Well, I'd already decided to change the diff ratio, so I'd have it out anyway...that was next.

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 03:10:38 PM
The trans synchros were in good shape, so I only ordered new gaskets and seals, new diff gears (2:76 instead of 3:44) and the shifter seal kit, as well as new speedo drive gears so the speedo would be correct. However, there is a tiny little lip seal in the speedo drive (where the speedo cable attaches) and that doesn't seem to come in any of the gaskets kits or even be available as a separate part. Here's where having spent a lot of years working on British cars comes in handy - also we have a pretty good British parts store locally - Victoria British - and they've been really helpful with the odd bits and bobs. That seal - like may parts used on British cars - are used thruout the different lines, and sure enough it was used on the Sprite trans also, $5 later I'm in bidness.

So first I needed to remove the layshaft so I could get the old oil pickup out.....the oil pickup is the tube going across the top of the gears in this pic, the layshaft is directly below that, and below the layshaft is another set of bolts holding the wire mesh screen at the end of the pickup tube.

Next I pulled the diff cover off so I could remove the diff carrier to change the driven gear - or the crowngear as the Brits call it.

The seals in those side covers are know to leak prodigiously, so new seals went in, but fortunately all the bearings were in good shape.....and everything got thoroughly cleaned in the solvent tank before re-assembly.

The new pinion gear is quite a bit bigger than the old one, and in order to make it fit (this ratio wasn't offered OEM in this year) You have to modify the bearing retainer that surrounds the gear. I marked out the clearance needed and went after it with a carbide burr in a die grinder. It took a while but fit perfectly when done.

Here's the new pinion gear compared to the old one....

(http://forums.kcminiclub.com/download/file.php?id=866)

And the marked up retainer ready for modification....

(http://forums.kcminiclub.com/download/file.php?id=870)

and here it is fitted over the gear....

(http://forums.kcminiclub.com/download/file.php?id=869)

And the new crownwheel installed n the carrier.

(http://forums.kcminiclub.com/download/file.php?id=867)

After that it was just a matter of cleaning, re-installing parts, torquing all the fastners correctly and it was ready to go......

The goldish colored tube is the new oil pickup, instead of collecting oil from the right side of the gearbox (potentially starving the engine of oil in hard right hand turns) it now goes into the middle of the gearbox and lies at the very bottom, ensuring oil delivery in either turn.

The large hole in the lower engine mating flange is where the oil transfers to the engine, there's an o-ring that seals this and that's where the hole I epoxy filled and drilled out in the block meets up.




Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 03:31:46 PM
With all that done I re-assembled the engine and mated it back to the transmission - along the way cleaning and repainting/refurbishing all the other parts that go on the engine. I rebuilt the starter with new brushes and bushings, it had a new water pump already, and heat wrapped the header. I did not rebuild the carb at this time as it had run just fine on the 1100 mile drive from Baltimore, and I also re-used the clutch as it also felt fine on the drive home. Both decisions would com back to bite me in the ass before it was over.

While reassembling the head, one of the worn parts I found was the rocker assembly -I had already ordered new Cooper S forged rockers but when I disassembled the rocker arm assembly to change out the rockers I found the shaft was worn badly, so before I could do that I had to source a new shaft. Vicky Brits didn't have one, and the usual suppliers were really expensive. Thanks to the web I found a British car dealer in Minnesota who had a lot of NOS parts and she had one for $15 brand new. Sold!

New Cooper S forged rocker arms

(http://forums.kcminiclub.com/download/file.php?id=885)

Compared to the stamped steel rockers originally fitted to this engine....

(http://forums.kcminiclub.com/download/file.php?id=884)

And the worn rocker shaft. Although I've seen worse, I just couldn't re-use this old shaft.

(http://forums.kcminiclub.com/download/file.php?id=883)

Once the new one came in I realized I had to make another trip downtown to the engine builder as the new rocker bushings have to be reamed to fit the new shaft - it took him all of 20 min to do them, and he didn't even charge me - Yay!

Once I had them all put together then it was on to the assembly of the block - and the next problem reared it's head!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 03:49:55 PM
The reason  bought a new block was so that I could reuse the 60 over pistons (no replacement for displacement, right? ), but these were pistons used a long time ago, and no one could come up with the correct rings - so it looked like I might wind up buying new pistons after all! However, my Google Fu seems strong and after about a week I found one of those tiny little obscure British suppliers in the Midlands that not only knew what I needed, they had them in stock in the right 60 over size too. their price was pretty reasonable at $80, but with shipping, customs etc it was more like $120 delivered. Still, at this point I was committed, so I ordered them, and when they got here I got one hell of a shock! This is the box they came in....

For those who don't know, Hastings is a well known and old line US engine parts company! So, just for fun and because I had some conflicting info on the correct ring gap I went to their website, where I discovered they stock rings for all manner of obscure Brit cars dating back to the 1900's! So after chasing all over the globe for rings for my car, turns out I could have gotten them "locally"!

I also spoke to a very knowledgeable young lady and got the ring gap info sorted out, so it was on with the build. A ring spreader sure makes it easier to load rings onto pistons....it's one of those $10 tools you don't need often in your home shop, but sure makes life easier when you do.

(http://forums.kcminiclub.com/download/file.php?id=876)

I also had to buy a new ring compressor, the one I'd used for 100 years to build American v-8's was just a bit too big for the Mini pistons!

(http://forums.kcminiclub.com/download/file.php?id=873)

(http://forums.kcminiclub.com/download/file.php?id=872)

I tapped the cam bearings in place and installed the lifters, then slid the cam in and buttoned up the lower end.

(http://forums.kcminiclub.com/download/file.php?id=880)


Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 04:04:39 PM
Here's another handy dandy little tool. How many of you have ever had your torque wrench recalibrated over the years you used it? How many forget to unwind the spring after you used it before you put it back in the box? Dollars to donuts it's not accurate. Before I do any major jobs I always recalibrate the torque wrench first, it's the only way you know you've got it right, otherwise you may as well use the ratchet and "elbow" calibration.......these testers were on sale at Harbor Freight for less than $30!

(http://forums.kcminiclub.com/download/file.php?id=879)

(http://forums.kcminiclub.com/download/file.php?id=878)

Coming together now.....

(http://forums.kcminiclub.com/download/file.php?id=881)

Head back on and most ancillaries installed..

Just checking the fit here, once the header was wrapped it was thicker and the heat shield under the carb hit it, so I had to pull it back apart and bend the heat shield a bit for clearance.

In the meantime I'd put a coat of black Rustoleum on the subframe and give it a week to harden off, before I started reinstalling the suspension bits. since I was working in my garage, I brush painted the subframe rather than spray, I felt I got a better coat of paint on that way and show car perfection wasn't the goal.....durability was. Suspension was next up....and more surprises were in store.

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 04:28:19 PM
Even tho I had been told the rubber donuts in the suspension were new, it rode like a rock and I dreaded every pothole, bridge approach or bump in the road, the worst ones really cracked my back on the drive home from Baltimore, so I decided to go with springs.

(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10246603_10202440139308739_6232120218532904008_n.jpg?oh=8cde0a765840a0087bad57876e5369e2&oe=5544E0FF&__gda__=1430056466_c05e11008d766d3b459badff0d1e243d)

The car already had hi-los on it, but the donut ones are different than the spring ones, so if anyone needs a set of like new hi-los for their rubber suspension, hit me up. I've been really happy with the ride on the springs so far, it's much more pliable without being soft and squishy.

I had already spent a ton of time cleaning and painting all the suspension bits, and I'd ordered al new rubbers along with new motor mounts and new subframe mounts. The ball joints were in fine shape, and when I checked the movement of the upper control arms they felt fine -moving smoothly and no slop in them, so I only ordered replacment seals and no bearings - ha!

Before I reinstalled the upper control arms I decided to remove the shafts and repack the needle bearings, that's when I found this....

(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10356360_10202555943803779_8026230923951601457_n.jpg?oh=838ac755926473e6d36302b766f2ee02&oe=55424BC2&__gda__=1425622831_53bcedba7863286ca8a20b35ee16abd4)

Both shafts were worn and galled something awful! So, more parts on the way - I didn't want to wait for another shipment from England and found the kits on sale at 7 Enterprises, so out came the credit card yet again and about a eek later I had them. I had to make a tool to drive the bearings and races out of the arms, but it's not that terrible a job and putting the new ones in is fairly easy. Once that was done it was just remembering where everything went and what went in first till it was all done.

(http://forums.kcminiclub.com/download/file.php?id=893)

Under the "in for a penny" theory, I'd also ordered new inner and outer CV boots for the axles, so that was next. And of course, I can't put new parts on old nasty axles so everything got torn down cleaned and repainted  before re-assembly. On teardown I'd found that I had roller bearings in one wheel hub and ball bearings on the other side, so I also ordered new rollers for both sides, and rebuilt the hubs too.....more cleaning and painting of course.

You install the inner boots inside out, install the tie strap and clip off the excess, then pull them right side out again.

(http://forums.kcminiclub.com/download/file.php?id=897)

Then the new bearing races get tapped into the hubs....notice I'm using a brass drift. Brass is softer than the steel race so I won't damage the race if it slips off as I hit it.

(http://forums.kcminiclub.com/download/file.php?id=898)

Bearings packed and installed into the hub, then the outer CV joint goes in, and gets packed with grease too...

(http://forums.kcminiclub.com/download/file.php?id=895)

Then you drive the rest of the shaft into the outer CV joint, till the snap ring on the end of the shaft locates in the groove in the joint. Usually one good hit with a dead blow hammer is all it takes.

(http://forums.kcminiclub.com/download/file.php?id=894)



Title: Re: 1980 Clubman Estate
Post by: Tim on January 03, 2015, 04:40:07 PM
Looking awesome.

I also teach in a tech department at a High School.  It really helps having all the heavy equipment there at your disposal.

I noticed the E-type in one of the pics.  That's on my list of cars to have one day.

Keep up the great work!!

Tim.
Title: Re: 1980 Clubman Estate
Post by: 94touring on January 03, 2015, 04:53:13 PM
Awesome write up!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 04:59:39 PM
So, with the engine back together, the subframe back together and all the associated bits and bobs cleaned and painted, it was time to take a look at where it was all going to go......and it was not a pretty sight!

(http://forums.kcminiclub.com/download/file.php?id=810)

There was no way I could put my nicely rebuilt and painted engine and my nicely rebuilt and painted subframe in there.....and not only that, I could see a  lot more work and more parts that needed to be ordered.....like steering boots for the rack, new brake master and clutch master cylinder kits, slave cylinder kit and hose.

The wiring was also a mess and I'd noticed on the drive home that the wipers would just barely move.

I also needed to decide what to do about the engine compartment color. It took another week of sleuthing to find out what the original color code was as it wasn't visible on the id plate but I'd decided it was champagne beige. I went to the local auto paint shop to have them mix me up a spray can, but they couldn't do it saying the formula called for color and hardener and of course you couldn't put both in an aerosol can. The best they could do was match it with regular enamel and put that in a pint, then use that to make a spray can up. I took the can home first and daubed a little on and it was horrible - not even close! So I brought the hood up for him to use to match and he went to work.....it took him three tries and the final result was close enough, but not perfect. Still I decided it was as good as it was going to get so I went ahead with the clean up to get ready for paint.

I stripped everything off the firewall and cleaned up with a wire wheel in my angle grinder, then went back over it with lacquer thinner and laid on a coat of self etch primer. In the meantime I'd found that someone had installed a clutch with the engine in the car - it's possible but extremely hard, and requires either a hole be drilled to allow you to get an impact on the nut on the end of the crankshaft, or to do what these bodgers did, slice the inner fender and bend it out of the way, then once the job was done bend it back and put a sheet metal screw in the bottom to hold it together. Grrr, that sort of bodgery really torques my shorts, but there was nothing to do but get out the welder and weld up the slash and refinish it again.

Here's where they cut and bent the right inner fender....

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10314662_10202493019350707_5482637506442342458_n.jpg?oh=7ee68a56c994e0defa64db358a5efd04&oe=5543CE12)

All welded up and ready to refinish, you can also see where the artful bodgers had been at it with their welder too

(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10347565_10202493031231004_6768550211701681453_n.jpg?oh=2befe7f9ae5278aa2b310f4c3eae1ae3&oe=553EA8A6&__gda__=1429004739_022d38b60e3a025c01b78fb47c527160)

Here's what the first attempt at the paint match looked like....that's when I decided to strip it all down and redo the whole engine compartment, up till this point I was just going to paint the worst parts and call it good.

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xpa1/v/l/t1.0-9/10312576_10202459376149648_1501756492128271283_n.jpg?oh=b70b6f6f4fb3bdece49a4278c859b385&oe=55342236)

And here's how it turned out in the end, I thought it came out pretty good actually.

(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10374466_10202538915218075_6500698488743566642_n.jpg?oh=7b56303252024ba40f6af2fc1807fe1d&oe=553332AC&__gda__=1430286778_7d76abb51cad8177ae98dd11ad4ed293)

I pulled the steering rack out and went thru it but other than needing a good clean up and paint and new boots it was in good shape. One more thing ticked off the list!

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10325241_10202440558399216_4827913398539771596_n.jpg?oh=16f4f23354425160ee8ea48c19c9deb4&oe=552FF425)

Steering rack reinstalled in the car....

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/10170955_10202485908452939_514972852676012580_n.jpg?oh=e25309e57747018a9509b0e02f66c5e9&oe=553C7782)


Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 05:16:17 PM
Quote from: Tim on January 03, 2015, 04:40:07 PM
Looking awesome.

I also teach in a tech department at a High School.  It really helps having all the heavy equipment there at your disposal.

I noticed the E-type in one of the pics.  That's on my list of cars to have one day.

Keep up the great work!!

Tim.

I could have drilled the ports out by hand, but the drill press makes it so much more accurate and straight. I have use of the entire school's shop but usually prefer to work at home. The exception is when I need to put the car on a two post to work underneath, or use the alignment rack or tire machines.

Yes, I rebuilt the E-Type too, I'm a glutton for British punishment! Go here if you want to read about the Jag..... thanks for the encouraging words!

http://www.cardomain.com/ride/505677/1969-jaguar-xke/ (http://www.cardomain.com/ride/505677/1969-jaguar-xke/)
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 05:37:42 PM
Next up, the wipers....

First of all, I was really perplexed why someone would cut and splice the wires like this, when there's an easily removed plug only 2 inches further up the harness?

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10334371_10202475099782729_2134895954339825385_n.jpg?oh=2ddd1d004a4c4a1805d435038cc2197e&oe=55413A64&__gda__=1429403506_4d22836226a304a5f83b2c6d6dadf6db)

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10341681_10202475100502747_4580616608989452630_n.jpg?oh=c68bfcd59b2d9e5c2d7b15c709d15545&oe=553728C1)

But that was only one of the wiring details I had to fix, there were many others......

The problem with the wipers tho wasn't wiring, it was the grease in the wheelboxes that had turned to rock and wouldn't let the arms move. I took it all apart and cleaned everything out, bead blasted and repainted the rusty bits and put it all back together -worked a treat when it was done!

(http://forums.kcminiclub.com/download/file.php?id=840)

(http://forums.kcminiclub.com/download/file.php?id=839)

Once that was done I decided to replace the firewall insulation, looking for any and every possible way to cut down on the din coming from up front. They only offer a generic kit now, you have to cut it to fit, and of course it goes in before anything else can be bolted back on the firewall.

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10173522_10202506789734958_8861680907985865966_n.jpg?oh=d8f55cf747ec015e12f83b9d088c8a1a&oe=5540F091)

Next up was to rebuild all the master cylinders, and add an extra fuse box to carry the load for the electric fuel pump, aux lights and the new Hella 55/100 halogens I bought. I didn't want to burn up the high beam or headlight switch with the extra load, so I also wired in relays.

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10356151_10202578566209325_4168143915991608420_n.jpg?oh=c1f6bc4d5412c9a2a7e7e1c5c203888d&oe=553955C0)

I had replaced both fuse panels with new ones and had a serious problem with a current backfeed that I spent a week trying to figure out - with the key off all the dash lights were on and many things didn't work anymore. I finally found the problem, the new fuse panels are bridged between two of the terminals, the original ones aren't. all it took was a few seconds with a dremel tool and everything worked normally again.

New fuse panels look like this.....

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10450851_10202696310112849_169936699470577975_n.jpg?oh=76b216eb15a3b77e8228ae59df5259e3&oe=552695F1&__gda__=1428948129_7462674a75a61542c76875260f883a7f)

Originals look like this.....

(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10353098_10202696310992871_1084899290012364311_n.jpg?oh=7dad6263b89a5b4ccec1a59a89e2c8f8&oe=553282E1&__gda__=1429698295_452e2edaf7b8076785567789b7d215bd)
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 06:14:01 PM
My goal all along had been to have the car ready to drive to Milwaukee over the 4th of July for the Mini Meet East meets West event, as you can tell by the dates on the pics, time was getting short and I still didn't even have the engine installed yet.

As it turned out, I went to the event, but Buzz didn't make it, but not for want of trying. In the end I was waylaid by "expert" advice......but I'm getting ahead of myself.

When I drove Buzz home from Baltimore, I had two instances where I lost power. In both cases it was really cold out and I was in the mountains of western Pennsylvania, going uphill. It came back again but since I didn't know what was going on for sure, I simply pressed on and it seemed to get better again on the other side of the mountains. I thought maybe it was carb icing as there was no preheat hose on the air cleaner. It always started and ran tho....and when it lost power I backed off on the throttle and it seemed to regain itself in a short while...but I was down to about 35-40mph going up parts of those hills.

I noticed the temp gauge barely got above the "C", I had been told it had fresh coolant in it and it was topped off so I figured maybe it just had too cold a thermostat in it, later I found out that the "coolant" looked more like mud and there was absolutely no antifreeze in it. It's a wonder it didn't freeze up in those mountains! Since I live in Kansas, and it gets HOT here in the summer, I wanted to make sure it would run cool enough for our climate so I paid particular attention to the radiator, I flushed it out thoroughly and got a ton of muddy nasty brown yuck out of it, same with the heater core. I wasn't worried that it was clogged as the heater had worked fine on the drive home - no fan, but plenty of heat - more wiring issues.
And the rattles! OMG this thing had rattles that were hard to believe, the worst of which was in the heater core - I knew that's where it was cause I could put my foot under it while I drove and it stopped or at least changed it.

So I still had a mountain of work to do before the event in Milwaukee.

Going back for a moment, in March about 2 weeks after I got home from Baltimore, we had another of our annual Classic Mini Fun Runs, this time starting around Steelville on the south eastern side of Mo. I took Buzz and I had a lot of trouble with the engine just cutting out - not missing, just running out of power like someone had shut off the key - similar to what happened  in the mountains on the drive from Baltimore only worse, as it did not recover, as the temps were now in the mid 60's I ruled out carb icing. Finally it died completely and I diagnosed a dead electric fuel pump. I went and bought a new one at the O'Reily's in Cuba, Mo and picked up a fuel filter too just in case. I also found I'd lost all my lights - headlights dash lights, everything but that turned out to be an easy fix, when I pulled out on the heater knob, the panel it went thru was loose (another rattle source) and pulled the wire connector off the back of the headight switch. Easy peasy..

I put the new fuel pump and filter in and bam it started right up and seemed to run with way more power. However, the next evening as we we headed back to the hotel it died again on the highway, but I was able to get to to limp back to the motel again. I decided to cut my losses and head back home a day early and in the morning it seemed to run perfectly again...about halfway home to KC it died again on the west side of Sedalia and I pulled over. I couldn't hear the fuel pump running so I tapped it with a screwdriver and it immediately came on..... the car started and ran perfectly again. Aha - another bad fuel pump, what were the chances?

So back to the overhaul.....

By now the engine compartment was done, and I was ready to start putting it back together at last. Even working by myself, the engine went in pretty easily, and I didn't even scratch the paint!

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10418342_10202661063311701_8149067514966711338_n.jpg?oh=aace25c9c616cf489393ba779693af40&oe=552BBD08)

On the drive home from Baltimore the alternator light had been flashing intermittently, but I was determined to get home so I just ignored it. when I started hooking up wires again I found out why - the wires were burned and broken on the connector on the back of the alternator - it's a wonder I made it home!

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 07:25:00 PM
The driver's seat had really hurt my back on the drive home so I decided to see if I could help it any, and pulled the cover off the seat. Fortunately the frame wasn't broken and all of the springs and diaphragms looked OK, but the headrest  on this car is on the end of a long tube that slides down inside the seat backrest.  The end of the tube had worn its way thru the foam padding and was hitting me in the back - no wonder it hurt over the bumps!

I pulled the covers off and installed a thick heavy piece of cardboard under the foam, then put new foam in the centers and edges of the seats......

(http://forums.kcminiclub.com/download/file.php?id=732&sid=717b4129b22a03776b755dd23411ccda)

It all went back together nicely and turned out well.....

(http://forums.kcminiclub.com/download/file.php?id=733&sid=717b4129b22a03776b755dd23411ccda)

Since then I've decided it's still miserably uncomfortable. A friend has a set of Miata seats in hi P'up and they're really comfy so I went looking for a set of those too. I found one set, but before I could buy them the owner sold the right side seat - which is the one I needed the most since my car is right drive. They also didn't have the sliders so I went to the local import breakers yard to see about a set of sliders he had. When I got there they were still attached to the seats - I made him an offer and bought the whole things. The left one was pretty tired but the right looked good and they were in a tan leather - not exactly a match but not bad.

I built some brackets and adjusters for height at the rear and I'm pretty happy with it. Next I need to make an armrest for the door.....but that can wait.

(http://forums.kcminiclub.com/download/file.php?id=947)

I also pulled the wood dash out and added some felts around the edges, that stopped some more rattles. I pulled the left door panel off and found loose screws, screws missing entirely and things rubbing, which fixed a whole bunch more rattles but it's still amazing how many rattles are still there!

Next step, get it back on the road in time for Milwaukee!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 07:54:51 PM
Here's how it looked about mid June, two weeks or so before the trip to Milwaukee on the 4th of July.

(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10432110_10202744086187221_8628778784686646431_n.jpg?oh=3b71c8b8832bec2f00eb1cc3c4ea8c18&oe=55333CBD&__gda__=1430402825_a5bd36c7574e899cce3443bbac96ef00)

Now it was time to get it on the road and get some miles on it.....

My buddy Don and I headed out of town for a 40 mile run to Lawrence on a nice 90* day figuring that would be a good test, we got no more than 5 miles out of town and the temp gauge was all the way up to "H"....not a good beginning. I was running a 165* thermostat but that clearly wasn't getting it.....so we let it cool down and drove back home to the shop. I checked everything I could and could not find anything wrong. Over the next week or so I drove it all over town and it never got over the "N" , unless I hit the highway, then it slowly and surely climbed towards the "H".

Finally I just ran out of time to do anything more, the day we were supposed to leave for Milwaukee the weather was cool, barely 60* - unheard of in Kansas and was forecast to be like that all weekend, I decided to just go and see what it did. I told the other guys that I would know in the first 50 miles if it was going to make it - it actually made 65 before it was almost to the "H" again. I was disappointed but sent the guys on and I went back home to get my 2009 MINI and drove it instead.

Probably a good thing too, as it was well into the 90's on the trip home especially across Missouri.

Once home and with the pressure off I started working thru everything I'd done. I pulled the water pump off to see if it had the deep impeller - it did.

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/10616406_10203222283301850_3972474059069812834_n.jpg?oh=5ba6710c59f7a0f1ad75f5dcf463a879&oe=55295914)

I checked the size of the pulley - I was told I needed the "big" pulley and that's what was on it, but I questioned that. Supposedly they had problems with the small pulley causing cavitation, hence the large pulley which is what was fitted on all the warm market cars.

I took the radiator down to a radiator shop and they pulled the lower cap off, they thought we'd find it full of crap blocking the tubes. it wasn't. Because it had a crimp-on tank they couldn't put it back together again so I bought a 3 core radiator. It was a little better now, I made the drive to Lawrence on another 90* day and it didn't get hot till almost there, and curiously - like always - once I got into town it cooled off again down to Normal.

What the heck was going on?

After thinking about it long and hard for a couple more weeks the light bulb finally went on - I had changed the diff ratio. The big pulley was for engines that turned a lot of RPM, my engine was only turning between 3 and 3500 on the highway. It wasn't cavitating, it simply wasn't turning fast enough to move the water under hot loads on the highway. I got a small pulley from the guy who sold me the Sprite block off of - you guessed it - a1275 Sprite and put it on.

The first event I did was in Sept, no overheating but then I didn't go too far on the highway. Don and I took another run, this time north to St. Joseph, Mo - about 100 miles roundtrip....and now I have the opposite problem!

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/10606622_10203541542123121_5714376013861833824_n.jpg?oh=83352318d3fc06404068fd73b7859521&oe=553DB92B)

As you can see, I decided to install a real temp gauge with numbers on it instead of relying on the L-N-H of the standard gauge so I could see what it was really doing - the numbers either side of the needle are 160 and 190 and the dash gauge is disconnected. As always the car runs normally in town, but now on the highway it only runs about 165, even with a 180* thermostat. Admittedly it was only 70* that day, but I've never had an engine that runs cooler than the thermostat setting. I've decided to leave it alone for now and see what it does later this summer when it gets hot again.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 08:14:25 PM
Of course, I wasn't done with Buzz....in fact, I still have projects to do even now.

But first I needed to do some more suspension work. The left rear trailing arm was toed out about 3* and the front end was close to spec, but I wanted it better, so I bought some more bits - adjustable lower control arms and tie rods. Now I could set not just the toe but also the caster and camber. I also got some rear camber/toe plates too.

(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10550960_10203045601444914_2593420997408972107_n.jpg?oh=0014b3319949d2bb55a32815abc0ba51&oe=5541BDAF&__gda__=1428767554_2eef591308284a95b6b1d4e99baa9519)

Everything if front really came in exactly where I wanted it, the thrust angle was almost perfectly straight too. The rear end came close, I will still have to do a little modifying of the left side camber plate but it's way better than it was.

Here are the front ones installed.....

(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10524657_10203046109537616_8324156305292730367_n.jpg?oh=30baf6013eb24a069959b1fe201a942c&oe=553BE7E2&__gda__=1429530895_238c8752a45557912f826971cfb9e0e5)


And here's how the rear ones bolt in for those that don't know.....the bracket has a slotted hole and the washer has ribs that match up with those on the bracket. This allows you to move it vertically for camber adjustment, an horizontally for toe adjustment. They're really simple to install, but you do need some one who knows how they work to do the alignment after the install.

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10626780_10203130295842221_4919024506930866842_n.jpg?oh=6591f98a0fdc91546d7887a605e95b43&oe=5533B3E8)

and here they are installed...

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/1896888_10203130297122253_3278994339338377607_n.jpg?oh=0d88f1ed0d1b974a06defc000358621b&oe=55249F55)

Still to do, I'm going to drop the rear subframe and clean and paint it like I did the front. I also want to take the fuel tank and have it sealed.

I have a new in box cruise control to install - I used to do these all the time back in the 70's - I even had one in my Porsche 914 and it worked beautifully. It will take some engineering to make it work on this carb, but I can do it.

I'm still chasing rattles - hard to believe given how many I've fixed, but there it is......

I have an electronic ignition to install too.

I've done about 2000 miles on the engine and it's just now starting to loosen up, fuel mileage has gone way up too tho I don't have any real, hard numbers yet.

I'm sure there's more, but my fingers are tired from typing!

Hope I haven't bored you all to sleep with my tale.......

Title: Re: 1980 Clubman Estate
Post by: MtyMous on January 03, 2015, 08:31:04 PM
Great build thread. I'm living vicariously through others right now because my funding has been diverted temporarily. Keep it up. This is motivating.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 03, 2015, 08:48:59 PM
I actually glossed over a lot at the end here....like the carb overhaul, the electronic ignition snafu, and having to pull the engine back out to replace the clutch that slipped under the extra new found HP from the overhaul!  ::)
Title: Re: 1980 Clubman Estate
Post by: Willie_B on January 04, 2015, 03:49:22 AM
I have enjoyed following along. Lots of great photos and story. Going to be a sweat driver. Others on your classic mini runs may have a hard time keeping up.
Title: Re: 1980 Clubman Estate
Post by: Merlin on January 04, 2015, 11:38:32 AM
There was some good info on using RWD engine blocks on a mini in here! I would love to see you split that off and go into a little more detail as getting 1275cc engines here are easy, as long as you aren't looking for a mini block!

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 04, 2015, 11:40:59 AM
OK, I'll start another thread on just that......
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 09, 2015, 12:06:27 PM
I guess no one noticed the speedometer..... ;D

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/10606622_10203541542123121_5714376013861833824_n.jpg?oh=83352318d3fc06404068fd73b7859521&oe=553DB92B)
Title: Re: 1980 Clubman Estate
Post by: MtyMous on January 10, 2015, 08:11:58 AM
First thing I noticed. Haha. But the car is so cold! Temp gauge not working? Or did you just move it over to the one on the right of the cluster?
Title: Re: 1980 Clubman Estate
Post by: Mudhen on January 10, 2015, 08:42:52 AM
Quote from: MiniDave on January 09, 2015, 12:06:27 PM
I guess no one noticed the speedometer..... ;D

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/10606622_10203541542123121_5714376013861833824_n.jpg?oh=83352318d3fc06404068fd73b7859521&oe=553DB92B)

4.gif
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 16, 2015, 10:59:13 PM
Quote from: MtyMous on January 10, 2015, 08:11:58 AM
First thing I noticed. Haha. But the car is so cold! Temp gauge not working? Or did you just move it over to the one on the right of the cluster?
I installed a new temp gauge to the right of the cluster, so I could get some actual numbers as to what it was doing. I would like to get the in-cluster gauge working too, but it's difficult to do as the sensor needs to be in the coolant flow.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 22, 2015, 10:51:29 PM
Today I started building a flat tow bar for Buzz, if I'm going all the way across the country in the dead of summer to make an event, it might be a whole lot better drive in a MINI with A/C and cruise control - towing a Mini of course.....

(http://forums.kcminiclub.com/download/file.php?id=962)

It's a little easier on a Clubman, the bar doesn't go thru the lic plate brackets like it does on a round nose Mini. I couldn't find spacers like Dan shows in his DIY post, so I ordered some tubing from McMaster Carr today, it will be here tomorrow and I can get it buttoned up and try it behind the Audi. I used 2"x2" angle iron, I think Dan used 1 1/2" in his article.
Title: Re: 1980 Clubman Estate
Post by: 94touring on January 23, 2015, 12:02:55 AM
Looking good
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 27, 2015, 11:00:22 AM
Yesterday the last bit of material I needed to finish my tow bar mount came in from McMaster Carr - some 1" OD X 1/2" ID tubing so I got my neighbor's chop saw and cut two 3" long sections. Once everything was de-burred and cleaned up I put it all together on the Clubby and it fit perfectly!

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10388131_10204094205179352_7514213012963706701_n.jpg?oh=685c9c7a6773bdf782fcb571df33c6b5&oe=556BDAF5)

You hardly notice it from above.......

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10955582_10204094205779367_9135875195432767692_n.jpg?oh=967e7f28b646b3384b9685afa1f0097a&oe=556255E8&__gda__=1431947927_b2a4cd303a9b879d9708c4f4c78ddbc3)

Next I need to find a round nose car so I can make whatever mods needed to fit their front end, then I can blow it all apart and take advantage of a rare warm couple of days in Kansas in January to get some paint on it - it's supposed to be 70° tomorrow! I also need to build some safety chains, but I have that figured out already.

Next I'll need to build some removable lights, my plan is to build them so I can set them inside the back of the car to shine thru the rear windows, that way they stay out of the weather and  theft proof. If I run a harness thru the car all I'll need to do is plug them in, if I get too lazy to do that I can simply run the harness thru the car and under the hood to the front to hook to the tow car. Still cogitating on that part.....
Title: Re: 1980 Clubman Estate
Post by: 94touring on January 27, 2015, 11:05:03 AM
Nicely done, glad it worked out for you!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 27, 2015, 11:10:04 AM
So far it looks like it will work well, I still need to drag it behind a car too.....thanks for the tips in the DIY!
Title: Re: 1980 Clubman Estate
Post by: jedduh01 on January 29, 2015, 07:24:01 PM
Much agreed- Tow bars are great!

Youll find great reward in yours with a +1 riding along!

Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 30, 2015, 12:36:51 PM
So Jedduh, no safety chains, no lights?

I've done the final design iteration on mine, I still need to make some brackets to attach the safety chains on Buzz, and buy some longer safety chains to hook to the tow car. I also had to raise the lic plate a little, the bracket was behind the plate and moving it up makes it easier to get the tow bar bracket on and off.

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10945726_10204112630439972_4257973539013701814_n.jpg?oh=2906c179a0e17e291cf074d877b6339e&oe=556A6189)

I also need to finalize my lighting arrangement, I bought some regular LED trailer lights thinking I would build a bracket to put them inside the car, but there's no good place to land a bracket that puts the lights in the rear windows.....still thinking on that one.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on January 30, 2015, 09:45:04 PM
Here are the safety chain brackets I built.......and the shortened chains. All I have left to do is the lights then take it out for a road trial. However, we have some nasty weather bearing down on us, so it may be next week before I get to do that.....

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10945020_10204114175278592_1353501474311504208_n.jpg?oh=e897681edf8b7c90e52d404403524c48&oe=55248448&__gda__=1432275550_49ed4f5222cf75ff5fc502b8eb1f11b7)

(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10363624_10204114175918608_8021853480869360957_n.jpg?oh=6a863f729599301a575a2b9ff25fdb8c&oe=55690FB0&__gda__=1431122405_92fa6844ce7be031c5bed6765636921f)
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 03, 2015, 11:53:47 AM
Got a coat of paint on my tow bar bracket, found some more safety chains for the tow vehicle end, now all I need is for it to quit snowing so I can take it for a test spin around the 'hood. I had planned to take Buzz up to school tomorrow to balance the wheels and do a final alignment on him, but the weatherman says otherwise.

Got to get him ready for our trip in March, it's only a little over a month away now.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 14, 2015, 05:57:51 PM
Next up, more electrical work......I thought I had all this sorted when I did the engine work, but on my last drive I found the following:

1) No heater fan - it was working,  I'm hoping I just didn't hook the ground wire up last time I had it down.
2) Brakes lights not working - they did. I don't know what's up with this....
3) Dash lights out - same thing, they used to work fine.
4) Turn signals - work but don't self cancel. I may have to make the cam if it's missing - I understand they were made from plastic and are no longer available.
5) Fuel gauge - wildly inaccurate. Fill the tank and it takes 75 miles to come down to F, in 75 more it's empty. I hope it's just a matter of bending the float arm.
6) Aim the headlights properly, they're close but need a bit more tweaking.
7) Move the fuel pump. Right now it's on the firewall, I'd prefer it's in the back near the tank.
8 ) Once the fuel pump is relocated, I can install the windshield washer reservoir and pump.
9) Install the Pertronix I bought months ago.

I also need to tidy up some of the wiring I did under the dash, and I'm contemplating swapping the spots in the dash for the temp gauge and tiny tachometer. I have a complete mix-match of gauges as it is, so it won't look any different to the uninitiated with a casual glance at the dash.

More as it happens....
Title: Re: 1980 Clubman Estate
Post by: tsumini on February 14, 2015, 08:58:20 PM
Just noted that you have 1980 era fuel gages so yours is a different animal than mine. DKlawson on the other board has talked extensively on these that need a voltage stabilizer.He may be able to help.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 14, 2015, 10:24:04 PM
Which other board is that?
Title: Re: 1980 Clubman Estate
Post by: tsumini on February 15, 2015, 06:18:57 AM
Minmania Sorry.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 15, 2015, 09:56:43 AM
Thanks!

Yes, I'm aware of how the voltage stabilizer works, my Jag has one too.

Right now it's just too damn cold to work in the garage, this stuff may have to wait a week or more till things get back above freezing. I have heat out there, but when it's in the single digits it costs too much to get it up to a comfortable enough temp to work.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 20, 2015, 04:40:14 PM
I'm down with the flu today, and I figured I could sit around all day feely badly or go do something in the shop, so I cranked up the heater and went to work finishing my tow bar.

I've got the tow bar itself finished, so now I'm working on the bits....like lights.

I could wire into the car's harness and just use the tail lights and turn signals in the car, but I wanted it to be easily removable, so when I show up at an event I can demount it with a minimum of bolts and fuss...and nothing would show to make it look like it had been towed.

So today I built some brackets to mount some LED trailer lights, they bolt on with only two bolts and I'll make the harness easy to unplug too. Still have some finish work to do, make some stiffeners so they don't vibrate and then get a coat of paint on them, but I think the concept is going to work fine.

I built them so that they'd be inside the car on purpose - out of the weather and not a theft target like the magnetic ones.

(http://forums.kcminiclub.com/download/file.php?id=970)

(http://forums.kcminiclub.com/download/file.php?id=969)

(http://forums.kcminiclub.com/download/file.php?id=968)

I only got in about 2 hours work before my feet got cold and I ran out of steam, I should be able to finish them tomorrow and build the wiring harness.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 22, 2015, 05:22:39 PM
Still down with the flu, but I decided to tackle one of the items on my Buzz list - why don't the turn signals self cancel?

Once I got the steering wheel off, I found the screw for the clamp for the T/S switch and pulled it off the column - with the switch off I saw the reason for yet another rattle - in this pic you can see a white plastic bushing between the column and the steering shaft - it's turned and not in the right place, that notch in the side is where the turn signal switch is supposed to locate. I have a new bushing so I'll put it in before I re-assemble the column. I can't say anything nice about the last guy who worked on this car, so I guess I just won't say anything.....

(http://forums.kcminiclub.com/download/file.php?id=974)

Once I had the switch off and studied it a bit, it became apparent why the self cancel didn't work. I didn't get the "before" pic, but this next pic shows a yellow part - that's supposed to be where it is now - before it was sitting on top of the switch. The yellow part has a nubbin that engages the works in the switch and it wasn't where it needed to be to make it work. Now how to fix it.

(http://forums.kcminiclub.com/download/file.php?id=973)

When I took that gold plate off of the switch all the little bitzas went flying, of course, so it took a few minutes to find them again and then a few more minutes of study to figure out where they all went, then it took about 3 extra hands to hold everything in place while I put the yellow cam back in, oriented it correctly and screwed the cover plate back. It still didn't work the first time, so back apart again. I made some helpers out of bits of wire and what have you to hold things in relation, then carefully worked the plate back on again.......success! It now cancels.

But that brought up the next problem.....my steering wheel is non-OEM, so it had no engaging lugs to fit into the slots on the cam to turn it with the wheel. I could have welded something fancy up with a couple of lugs and a flat plate to attach to the wheel's hub, but I went simple, and tapped a couple of 6-32 holes and locktited in some screws - there's very little force on this part to make it work so I think this will do, but if it doesn't it's right on top and I can get out the welder and fab something better up.

(http://forums.kcminiclub.com/download/file.php?id=972)

So, that's several mysteries solved all at once.....while I had the column out I replaced the upper bushing and lower felt bushing with new ones I already had, once everything was in the correct place the column tightened up like it was brandy new. Once I get it all re-assembled the signals will self cancel too. While I have the column out I'm going to re-install that blue hose - it feeds fresh air to the heater core and with it loose like it is it brings huge amounts of cold air right on my feet, not what you need on 30° or colder days like we've been having. Before I do any of THAT tho, I need to get my head up under the dash and see if the  brake switch wires are undone, if that's not what's keeping my brake lights from working, I'll want to dig deeper before putting everything back together again. Oh, and see why the heater fan stopped working too.....

At least I made progress......
Title: Re: 1980 Clubman Estate
Post by: jeff10049 on February 22, 2015, 08:52:01 PM
Nice. I decided to tackle my steering this week also.
Should the felts be oiled?

Jeff
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 23, 2015, 08:09:38 AM
Yes, the felt at the bottom should be soaked in light oil overnight, then squeeze out the majority of the oil so it doesn't drip on the carpets, then put it in.....I don't understand why they they use the felt on the bottom and not just put in two bushings like the one at the top, but they musta had their reasons. I also took the shaft to the fine wire wheel on the grinder to polish it up a bit.

I used PTFE on the upper nylon bushing, not grease. If it goes to squeaking (which I don't think it will) after some miles, it's easy to get at to get some spray lube into it.

One other interesting note, the large nut that holds the steering wheel on was finger tight........ ::)

I'm also going to see about switching the turn signal lever over to the left side of the column, I think it's easy on this car and that way it'll be like all my other cars and I won't occasionally be signaling a turn with the wipers.  ::)
Title: Re: 1980 Clubman Estate
Post by: tsumini on February 23, 2015, 08:29:14 PM
Quote from: MiniDave on February 23, 2015, 08:09:38 AM


I'm also going to see about switching the turn signal lever over to the left side of the column, I think it's easy on this car and that way it'll be like all my other cars and I won't occasionally be signaling a turn with the wipers.  ::)
That I found out was the hardest thing about RH driving in Australia.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 07, 2015, 04:12:04 PM
Today I replaced my clutch master cylinder, which seemed to fix my hard shifting issue. I'm pretty much ready for our fun run that starts next week!
Title: Re: 1980 Clubman Estate
Post by: Mudhen on March 07, 2015, 04:48:08 PM
Quote from: MiniDave on March 07, 2015, 04:12:04 PM
Today I replaced my clutch master cylinder, which seemed to fix my hard shifting issue. I'm pretty much ready for our fun run that starts next week!

4.gif

Lots of pics, please! 62.gif
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 07, 2015, 06:26:46 PM
Not much too see, the hardest part is getting the clevis pin off the pedal linkage, I had to enlist a younger, more bendable guy to help me with that. We still had to remove the driver's seat so he could get contortioned into place to get it.

Other than that it's remove the line and two bolts and she's out. Installation is the reverse as they say!  ;D

To bleed it I just run a tube up from the bleeder screw into the reservoir and pump till I don't get any more air - then she's good to go.

I may get some static for not using the period correct metal can reservoir instead of the plastic one, but my main goal was to get it driving properly.

Job Done!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 08, 2015, 06:35:41 PM
Today I tackled the next project - when I did the engine and subframe work I put all new bushings in the control arms, but lately it had started to pull slightly under braking, and I wasn't happy with the alignment - I think I found the culprit on both problems.

These bushings are new OEM rubber, 9 months and 3K miles old......I'm going to replace them with poly bushings. This is the right side....

(http://forums.kcminiclub.com/download/file.php?id=977)

And the left side wasn't much better. Next up, back to the alignment rack!

(http://forums.kcminiclub.com/download/file.php?id=978)
Title: Re: 1980 Clubman Estate
Post by: 94touring on March 09, 2015, 07:37:49 AM
Only 9 months huh?  That's discouraging.   
Title: Re: 1980 Clubman Estate
Post by: Mudhen on March 09, 2015, 07:52:10 AM
Ya, imagine if you were racing it?  Just plan on swapping them out every couple of weeks... :(
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 09, 2015, 08:32:27 AM
I'm told the poly ones hold up well....we'll see. I'm going to be driving about 1,000 miles next week, that should be a good test.

I think the racers change them out for rod ends instead.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 27, 2015, 09:49:04 AM
After our Fun Run in Arkansas I decided to pull the dash and upgrade a few things and make some changes, also to look for those last few rattles and buzzes still in the dash, much to my frustration.

First thing I did was replace the two switches on the steering column - I did this for two reasons, first so I could fix the self cancelling problem and second so I could change sides and have the signals on the left instead of the right. That was fairly straightforward, two new switches and some longer screws on the back to activate the self cancelling mechanism was all it took.

(http://forums.kcminiclub.com/download/file.php?id=991)

Next I pulled the main dash panel - I have several things to do here - I'm going to move the tach to the right side of the dash so it will be easier to see when driving, consequently the temp gauge will get moved over to the main panel. All that moving required a new wiring harness for the tach, and while I was making that I decided to upgrade the connector so it's easy to disconnect and remove that side of the dash. I also had to make a bracket to attach the tach, before it was just a press fit in the wood dash. I was surprised that my local Ace hardware had the 4mm nuts and washers that were missing too.

Here's the tach, bracket and wiring connector I made installed in the wood panel.

(http://forums.kcminiclub.com/download/file.php?id=993)

I also had no dash lights and pulled the instrument cluster to find the reason, which was pretty obvious once I got it out - there was a burned spot in the circuit board - it probably happened when I last had it out, I probably touched something and grounded it out. I found a guy nearby that has a video repair shop and he soldered it up for me - he also put some JBWeld over the top to protect it - I wouldn't have done that but whatever....

(http://forums.kcminiclub.com/download/file.php?id=994)

Lastly, swapping the tach and temp gauges means a new harness for those gauges too, for the lights and also I swapped the amp gauge for a volt gauge -the amp gauge was woefully inaccurate. Now all three gauges match too...

(http://forums.kcminiclub.com/download/file.php?id=990)

(http://forums.kcminiclub.com/download/file.php?id=992)

Now, all I have left is to make the car side of the harness for the tach and then re-install everything. I'm hoping to get it all done today so I can take Buzz to the KC version of Cars and Coffee tomorrow morning - it's moved from the previous location at the Roasterie to the KC Auto Museum, but it's a mere shadow of the events in Dallas and Charlotte, let alone California.....with more late model stuff than classic. But I'm hopeful that as the weather improves maybe more cool cars will start to show.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 29, 2015, 04:53:26 PM
The KC Cars & Coffee show was really well attended, tho there were way too many late model Porsches and BMWs and not enough cool, classic cars. Still, even tho it was cold (38° !) there were a lot of people there - so many that the venue was over crowded, I wonder what they'll do when the weather gets nice?

So today I finally found my dash rattle.....after taking out the steering column, instruments, the wood dash itself and the covering behind the dash, I'm left with this rubbery sort of insulation that's next to the firewall - when I tap it with my hand I get that obnoxious noise I've been hearing. Now, how to fix it....

(https://scontent-dfw.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11072929_10204469224994613_3265782672141452146_n.jpg?oh=bccd7cd02dbb7f02f6bc6dddba3cf83a&oe=55A9766D)
Title: Re: 1980 Clubman Estate
Post by: 94touring on March 30, 2015, 08:17:57 AM
If it's foam, I remove it.  Holds water especially on the ends and will rot the bulkhead. 
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 30, 2015, 04:24:07 PM
No, it's not that, it sounds like there's something metal behind it that's causing the noise......Ima hafta take it out and see what's in there.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 31, 2015, 04:47:31 PM
Good point, it shouldn't hurt anything since he only put it over the solder repair he did to that one strip, but I'll need to be careful not to contact it with a ground when it's live.  I learned my lesson tho, I only work on electrical stuff with the battery disconnected! It is really close to that other circuit tho, isn't it? I'll have to look at it really closely and see if it touches, although there's a clear coating over all of the circuit board that should insulate it from the JB weld.

Today, I finished the instrument wiring harness and connector - now all I need to do is figure out how I'm going to secure that loose insulation and I can start putting Buzz back together again - assuming everything works of course!  I snuck a borescope down behind the insulation and didn't see anything loose that could rattle, I'm wondering if it was just hitting the sheet metal? Something made a racket when I first patted on it, that has now stopped. I might just put some good old duct tape on the top edge to secure it and call it good.   

(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xta1/v/t1.0-9/11088401_10204480521237012_5417592567960294263_n.jpg?oh=c3f436b3cb20a7e31477fa5d8ada9921&oe=55B9F88E&__gda__=1433386947_abaf50b7b9f15450db6c8cec13d760af)

(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/11081101_10204480571478268_3967823624869231477_n.jpg?oh=37e7274a3e4a948a4d8bbc0d8d16234c&oe=55714AD9&__gda__=1437655759_ff69d590d1e5eebc0641e1cc3a8b97ca)
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 13, 2015, 08:16:35 AM
Today I made one of these, the old cardboard that formed the floor of the glovebox was tired, bent, dirty and nasty - someone had made another out of a for sale sign, but it wasn't any better and looked like shite from under the dash - not that anyone looks under the dash -  so I cut and bent a new one out of shiny new steel.

(http://forums.kcminiclub.com/download/file.php?id=1002)

And here's where it goes, the old one hung down thru that large hole......

(http://forums.kcminiclub.com/download/file.php?id=1001)

And here it is in situ, I'll put a few screws in it to keep from introducing a new rattle, and there's a mat that goes over it to become the inside of the glovebox....then it's time to start putting Buzz back together again. The club has a run scheduled down to southern Mo next weekend and I want him ready for it. The guy who owns the 13" wheels said I could use them on that run, so it will be a chance for me to see what they're like in all driving conditions, town and country. Our route will take us down Rt 66 from Joplin and thru all 13 miles of the mother road in Kansas!

(http://forums.kcminiclub.com/download/file.php?id=1000)

A few of our stops along the way......

(http://injohnnaskitchen.com/wp-content/uploads/2015/02/spencergarage-640x475.jpg)

(http://injohnnaskitchen.com/wp-content/uploads/2015/02/gayparita.jpg)

(http://injohnnaskitchen.com/wp-content/uploads/2015/02/carsontheroute-640x480.jpg)

These pics were from the route planner's pre-run last weekend, we have reservations for lunch Sunday  at this Cafe on the Route, it was formerly a bank, and in it's previous life it was robbed by Jesse James...

(http://injohnnaskitchen.com/wp-content/uploads/2015/02/cafeontheroute-640x461.jpg)

If the weather co-operates we're gonna have a great run. Right now it looks like about 20 cars will be participating, 3-5 classics!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 16, 2015, 04:16:45 PM
I got Buzz all re-assembled this afternoon and took him for a quick spin around the block - he started right up and ran perfectly and all the electrical stuff worked just as it should have done. It's a little disheartening to work so hard for so many weeks and when it's all back together it doesn't look, run or drive any differently - but at least everything worked!

So  took him around the block and when I got back I got a nasty surprise, a big ol puddle of brake fluid under the left rear wheel. I haven't done anything to the rear of the car since I got it, although I did pull the drums right before our Arkansas run last month and everything looked fine then.

(https://scontent-dfw.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/11118858_10204588395653805_4114677591329936782_n.jpg?oh=ed7bb3659e823e63ad8324a5bbdc2f55&oe=55A0B3D7)

I made a quick sprint up to Victoria's British Secret (well sorta, the road destruction around here this year is terrible, I wasn't sure if I could get there from here - or back!) and bought two wheel cylinders and incase those didn't fit, two wheel cylinder repair kits - I'll tackle this later tonight. Tomorrow I'm meeting John at school to align both cars to get ready for our Rt 66 trip this Saturday and Sunday.......it's always sumthin with these old cars.   :roll:

Oh, and now it looks like it's gonna rain all weekend around Joplin.....
Title: Re: 1980 Clubman Estate
Post by: Mudhen on April 16, 2015, 04:38:46 PM
I forget which thread I was in on [I think] northamericanmotoring.com - paging through I see, 'MiniDave' - hey, I think I know that guy!

Contributing all over the place.    4.gif
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 16, 2015, 07:16:30 PM
That's me, I sprinkle my little bon mots everywhere!

Turned out the Victoria British parts were correct - exactly the same as on a Spridget - and I got everything cleaned up and put back together tonight - last thing I have to do is install the clip that holds the wheel cylinder in, and it is being a be-otch! Of course there's a special tool to do this job that I can buy from any of the usual suspects, but that's not gonna help me tonight at 9 pm....I'm sure I'll figure it out....

(http://forums.kcminiclub.com/download/file.php?id=1003)
Title: Re: 1980 Clubman Estate
Post by: jeff10049 on April 16, 2015, 08:54:43 PM
Those clips are a bitch after ruining/bending one on my 60 trying to install. I looked up he cone shaped tool and decided to just go back to the wavy washer snap ring combo that was original to the 60. I don't know where one could find the wavy washers to use that setup on the newer cars but its quick and easy.

I suppose one could buzz out a cone on the grinder and use a socket and c clamp to push the ring on. I found trying to push it on like a c clip will only ruin it.

Jeff
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 16, 2015, 09:42:36 PM
After looking around I found a guy who told how he does it, and I used his trick and it worked. You bend one tang end, wedge the cylinder so it won't push back out, then slip it over the end, engage the two tangs first, then take a drift and tap the last one straight again. It pops right into place. Done deal.

Right after I got it on, one of my local Mini buddies said he has the tool......oh well......
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 23, 2015, 07:03:07 AM
One of the last things I've wanted to do on Buzz is the rear subframe and all the associated parts. Plans are to have the subframe powder coated, rebuild the brakes with new shoes, hydraulics and paint everything. I'm also going to drop the fuel tank and have it cleaned and redcoated inside, then move the fuel pump back to the rear where it belongs. I also have an idea on a rear sway bar that I'm going to try and engineer.....so, stay tuned to this channel!

I may have found one of the few remaining rattles too - the check straps for the rear doors. They pass thru a small guide loop and I think it used to be coated with something, I wrapped a couple layers of tape around it just to see if it makes a difference, if not then it could be the check strap itself, the rubber stopper on mine is shrunken and pretty hard, but I can't find anyone who sells them - they're easily found for the front doors, but the back ones are made differently. The quest goes on.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on May 07, 2015, 06:20:33 PM
Having gotten thru our Donut Run weekend, I need to get ready for our next fun run, the KC Mini Club and the Iowa Mini club do a joint event every May on some great roads in northern Missouri/southern Iowa. The fellow who organizes and runs the event is the guy who bought my '03 JCW from me - he traded it in a year later for a new JCW but I think he sold that when it ran out of warranty and is Mini-less right now, but he wanted to do the event anyway.

So, after I had a wheel cylinder start leaking on me I decided to replace all the brakes, the rears shoes are not worn out - in fact they look almost new - but after doing the repairs the left rear was still grabbing, as I cleaned up the shoes but didn't have time to replace them, and they were contaminated with brake fluid.

My front pads are also like new, but when you see the old rotors you'll laugh -  they look like they've been lying in a puddle of water for a couple of years and have some deep pits - I just looked at it like they were "drilled" or "slotted".......but I decided to replace them too as Moss had them on sale for only $40 ea.

I took the rear drums up to school today and turned them on the brake lather - they had worn typically out of round, so it took a bit to get them rounded out again, and as you can image such tiny drums are difficult to machine. I took me a while to get the lathe set up to where everything fit and worked, then a lot of passes to get them cleaned up and smooth, but in the end I only took off about 25 thou and they turned out great. While I was there I put them in the bead blaster and cleaned off all the old rust and paint. The right side drum had either been doing all the work or grabbing as the paint was burned brown on that side compared to the yellow paint on the left side.

(https://scontent-dfw.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11200769_10204714600528848_4162843126468200215_n.jpg?oh=0a07d2584a9ef35fb83b84919095187c&oe=55DB1143)

(https://scontent-dfw.xx.fbcdn.net/hphotos-xtf1/v/t1.0-9/14680_10204714653250166_5890303126966769193_n.jpg?oh=ba3a50f57f7d016547491b8d57623663&oe=55C133EA)

Tomorrow if it ever stops raining I'll get some paint on them, then Sat I'll get everything cleaned up, installed and adjusted correctly.....I'll also get to try out the fancy schmancy e-clip installer, as one of the club members has one to loan. I also have new rear brake hoses to install, mine are fine, but they're pretty hard and stiff.

Sat also I'm going to put the almond green car in the post above back on the alignment rack, the camber adjusters somehow worked loose (not my fault, my back was hurting the day we aligned it so he was under the car making all the adjustments) so this time I'll do the alignment and set it up the way I like it. Don is really happy with his P'up now that I aligned it - I don't know why it took so long for him to let me get it on the machine - but he's been fighting the poor alignment done by another shop for more than 5 years now. Bottom line, it drives great now! I'm going to see if John will let me set his up the same way - he currently runs a lot of camber front and rear (1.5 degrees), I'd like to see him reduce that to .5 degrees - I'm confident he'll like it better.

Oh, and all the electrical stuff I wrote about before our Donut Run trip worked perfectly!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on May 12, 2015, 08:06:45 AM
Well, Sat we got John's almond green S on the alignment rack and straightened out -  it didn't take a lot either.....turns out the left rear camber adjuster had slipped - again, he tightened them the last time - I tightened them this time, I don't think they'll move again. Between that and front tires down to the wearbars, he felt pretty unsettled driving home on our donut run - and no wonder, the storm we drove thru was huge, super high winds that constantly changed directions, rain bucketing down....Buzz was moving around quite a bit too.

However with the rain and family requirements I didn't get much done on Buzz. In between thunderstorms I did get outside and get some paint on my drums, so they're at least ready to install. Also, I picked up the new shoes and hardware from the local Brit Car Parts supplier - it sure is handy to have these guys in town - while they don't carry any Mini parts, many Sprite/Midget parts are identical, like these brake shoes and the wheel cylinders I bought a week ago, and their prices are pretty good - plus no shipping!

(http://forums.kcminiclub.com/download/file.php?id=1017)

Our joint run with the Iowa club will happen rain or shine, and right now the forecast for Sat is 90% chance of rain and thunderstorms, if it stays this way (it's the midwest, the forecast can reverse in the same day) then I'll leave Buzz home and drive the Blue Max instead.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on May 16, 2015, 02:30:42 PM
Buzz is alive!

(again)

When we came home from the Donut Run the weather was really bad, storms, wind, rain bucketing down - so when it got close to town even tho I was well down into the red on the fuel gauge, rather than stop I pressed on and just made it home.

A few days later Don and I were going to do a quick check ride to Lawrence after getting his alignment straightened out and I started Buzz and let him idle in the drive - just in case I had added a gallon of gas I had in the garage so I knew could make it to the gas station just a few blocks down the street - he ran for a minute or two and then died and would not restart. I could hear the pump running but the carb was drier than a popcorn fart.

I went ahead and finished my brake job this week and today went back down to the shop to see if I had a bad pump or a clogged fuel line or what was going on. I blew the line back to the tank and it seemed clear. The pump filter was clear. I ran down to the gas station and got another 4 gallons of gas and added that to what was already in the tank but it still wouldn't work. So I got a short length of hose and a one gallon gas can and hooked it to the pump - it took a bit before it pulled the fuel, but once it got liquid into the pump it worked like mad! I hooked the car's fuel line up and bingo - gas to the carb. Once it was full I cranked him over and he started right up and ran normally.

Tomorrow is the annual Westwood Micro Car Show (one of the few times when my Mini looks like a big car!) and I had entered Buzz along with Don's P'up so I really wanted to get him running again so I could make the show. It's going to be hot and muggy, typical Kansas summer weather, so I'm going to get there early and get one of the few spots in the shade! Pics tomorrow afternoon when I get home......
Title: Re: 1980 Clubman Estate
Post by: 94touring on May 16, 2015, 03:28:01 PM
When your drums were out of round did you get vibrations or a wobble when braking?   I thought I was going to be able to reuse mine but they don't seem right.  Stops but shaky if I get on them.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on May 16, 2015, 06:39:53 PM
Yes, some shaking on hard braking, and most noticeable at very light braking when coming to a stop.

But mine cleaned up easily at only 20 thou or so.....

I think most of mine was due to contamination of the shoes with brake fluid from the leaky left wheel cylinder.

I also found the backing plate loose on the right wheel, I imagine tightening that up will help immensely!
Title: Re: 1980 Clubman Estate
Post by: 94touring on May 16, 2015, 07:06:12 PM
Considering all the cylinders on mine were leaking, I'm sure that hasn't helped.  I have a set of new shoes and some mini fins I can throw on an end for now.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on May 31, 2015, 10:43:24 AM
Short report on the braking since I did the rears, substantial improvement - no shaking or pulsating at low speeds and it almost feels like the back squats a bit under harder braking. You can even feel the difference on light braking - how there's considerably more effort in the rear but no lockup.

Overall, I'm pleased.

I did not get the rear subframe pulled tho, I still have that to do but first I need to get my shop back in order - it's a mess!   

My wife bought me some clear container tubs so I'm going to put together my travel tubs - with various parts, electrical bits and tools, so when I take Buzz on a long trip I can just load the tubs and go.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on June 21, 2015, 01:13:09 PM
Today I took Buzz up to school to relocate the fuel pump back near the gas tank, I never wanted it up under the hood, but that's where I was when I got him and I just hadn't engineered a solution to move it yet - today was the day.

It's hot here, about 100* this afternoon and the fact that I needed to have the underside clear meant driving up to school to use one of the two post lifts. On the ride up I kept an eye on the temp gauge and it seemed to run about 195* or so, but after pulling off the highway while siting at a light it went way over 200. When the light changed and I got rolling it came down a bit......

I got the pump relocated and a new wiring harness made up, so for the ride home I decide to open my aux cooler to see what impact it had - it never got over 180 - which is the thermostat setting.....so I'm thinking that's gonna do the trick. I need to take a longer run but I'm encouraged....

A local classic Mini friend took my 10" wheels up to his local Wal Mart where his buddy works and had him balance them for me - I have to say he did a great job, they're the smoothest they've ever been since I owned the car! One more tick off the to-do list......

I really want to do Minis in the Mountains the first week of August in Aspen and take Buzz but I'm not sure I can do the state of Kansas and eastern Colorado in 100* + temps - OTOH, if I use the tow bar I can cruise in comfort in the Audi, and I'm pretty sure it won't be that hot at 10,000 feet!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on July 13, 2015, 09:42:54 AM
On my last little drive in the superhot weather I noticed my electric radiator fan wasn't working, so I decided to dig into that and find out why....I added an aux fuse panel when I rebuilt the engine and ran the fan thru that so it could get it's own fuse..... without giving all the boring details, I had attached one of the wires to the wrong side of the main fuse, so everything was actually running thru that one fuse - when I hit both the high beams and the driving lights it was more than the fuse was rated for, so it blew.

Moving one wire solved that, and a new fuse had everything up and running again.
Title: Re: 1980 Clubman Estate
Post by: 94touring on July 13, 2015, 10:25:21 AM
I like how you have things labled.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on July 13, 2015, 11:20:48 AM
Yes....well, I have a label maker and I'm not afraid to use it!   ;D

Actually, that's for me as much as anything, a week after running the wires I can't remember what they're for unless I label them!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on August 04, 2015, 02:20:38 PM
We've had high 90's temps the last few weeks and while the wife's Audi is laid up waiting for parts Buzz has been my DD, this has given me plenty of opportunity to check out how my heater core/extra radiator will handle the heat and so far it's been a rousing success. I haven't gone thru the extremes that Willie B did on his trip to BC, but I'm convinced it would handle it just fine.....

I think Buzz is going to be fine..........at last!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on September 01, 2015, 01:28:30 PM
I see all the pics I linked to in this thread from Facebook are gone, even tho they're still on my Facebook page, so I'll go thru and post them up directly to the site - sorry bout that, I didn't know Facebook would break the links like that after a period of time.

Nothing more frustrating than pictures that disappear from a thread.....
Title: Re: 1980 Clubman Estate
Post by: 94touring on September 01, 2015, 02:15:13 PM
I do have a free gallery here that you can mass upload to.  They will never disappear!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on September 01, 2015, 02:53:50 PM
OK, thanks - that will make it easier to insert them chronologically in the narrative - thanks again!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on October 08, 2015, 06:12:09 PM
I put in a new speedo cable, but first I had to make a tool to get the transmission end nut loose. The old cable worked OK but it uses a plastic end that had a tab to lock it in place - said tab was broken off and gone so I was using a screw clamp to hold it in place. Now it's correct.....I also got one longer than normal so I could run it any which way I wanted.....getting the firewall grommet out and back in was a royal PITA.

I'm trying to get my "Hot Spark" unit to work so I can eliminate the points set.....no joy yet on that. I'm also going to change the oil so I should be good to go on our trip next month.
Title: Re: 1980 Clubman Estate
Post by: 94touring on October 08, 2015, 09:34:06 PM
I have a new speedo cable to put on my car and need some kind of tool to reach the bottom.  Why I didn't do it when I had the subframe lowered is anyone's guess.   :-[
Title: Re: 1980 Clubman Estate
Post by: MiniDave on October 08, 2015, 10:44:43 PM
Did you see this tool I made? It was pretty simple to make and worked a treat!

http://www.restorationmini.com/forum/index.php?topic=832.0 (http://www.restorationmini.com/forum/index.php?topic=832.0)

(http://www.restorationmini.com/forum/index.php?action=dlattach;topic=832.0;attach=3345;image)

(http://www.restorationmini.com/forum/index.php?action=dlattach;topic=832.0;attach=3346;image)
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 23, 2016, 10:58:10 AM
Another thing off the list.......in the never ending quest to rid Buzz of the reason for his name, I found and fixed yet another annoying rattle - this one turned out to be the check straps for the rear doors. The check straps have a rubber bump stop at the end that is composed of several layers of rubber, then a washer and a rivet to hold the whole mess together. Over the years the rubber has dried out and shrunk slightly, so that washer was able to vibrate creating one hell of a racket! New ones you say? Unavailable according to all the usual suspects - front door check straps - sure, all day - but these are different.

My fix? A little clear silicone squirted into the gaps between the strap and the washer and rubber stopper. Ahhhhhh........it's so quiet now!  ;D

Still several more to find and fix but I feel like I've really made progress.....between putting screws and bolts back in that were left out and tightening things left loose, adjusting things that were hitting where they shouldn't and so on - buzz may actually lose the reason for his nickname once and for all!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 23, 2016, 11:25:03 AM
And yet another one ticked off the list:

When I first put the engine together in the spring/summer of 2014 I had bought a points elimination kit (like Pertronix but 1/2 the cost) from a company called Hot Spark in Austin, Tx. I put it in but never could get it to work,, so it went back in the box and I put points in which worked perfectly for the next year and a half, In the meantime I sent the old one back and they sent me a new kit, a few days ago I decided to give it another shot.

I installed the new kit just like before, but this time when I turned the key it fired right off! I got out the old timing light and set the timing and this weekend drove Buzz on about a 250 mile run with the KC Mini Club, Buzz has never seemed smoother!

I'm going to like not having to ever fuss with points again.....

http://www.hot-spark.com/ (http://www.hot-spark.com/)

Title: Re: 1980 Clubman Estate
Post by: 94touring on February 23, 2016, 12:10:13 PM
After going pointless on my 998 I'd never go back.  Glad you got it to work!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 23, 2016, 12:29:43 PM
Still don't understand why I had to change plugs after so few miles, but if I have to do it again I'll know it's not the points/coil at least. If I have to change plugs again shortly, what brand do you all use?

I put Champion N9Y in the last couple of times as that's what was in it.
Title: Re: 1980 Clubman Estate
Post by: 94touring on February 23, 2016, 01:05:07 PM
Ngk's
Title: Re: 1980 Clubman Estate
Post by: MiniDave on February 23, 2016, 01:52:15 PM
Do you remember what number?
Title: Re: 1980 Clubman Estate
Post by: Spitz on February 23, 2016, 02:20:02 PM
BP6S      BPR6S is more readily available however
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 04, 2016, 01:52:04 PM
.....
Title: Re: 1980 Clubman Estate
Post by: 94touring on March 04, 2016, 01:58:33 PM
So he bought it huh? 
Title: Re: 1980 Clubman Estate
Post by: MPlayle on March 04, 2016, 02:05:53 PM
Somebody bought Buzz?
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 04, 2016, 03:17:08 PM
Headed home to Texas, with a smile on his face!
Title: Re: 1980 Clubman Estate
Post by: jeff10049 on March 04, 2016, 09:16:42 PM
What just happened?
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 04, 2016, 09:28:45 PM
He made me an offer I couldn't refuse!   ;D

The happy new owner.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 05, 2016, 07:07:24 AM
Before he left with the car he handed me a paint pen and insisted I do this.......I was rather touched......
Title: Re: 1980 Clubman Estate
Post by: Willie_B on March 05, 2016, 07:39:22 AM
Time to dust off the Jag and get it ready to drive.
Title: Re: 1980 Clubman Estate
Post by: MPlayle on March 05, 2016, 07:49:42 AM
So, where in Texas is it headed?

Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 05, 2016, 07:54:34 AM
Quote from: Willie_B on March 05, 2016, 07:39:22 AM
Time to dust off the Jag and get it ready to drive.

Yep!

I also have a considerable amount of deferred maintenance to do on the Audi and 2009 Clubby.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 05, 2016, 07:55:31 AM
Kilgore, Tx.....he says it will be driven almost every day, although he also has a 2016 F JCW - his 5th new MINI......
Title: Re: 1980 Clubman Estate
Post by: towjoe on March 05, 2016, 03:44:52 PM
Did you list your clubman estate for sale anywhere?
Regards
Joe  77.gif
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 05, 2016, 06:16:42 PM
No Joe, he was referred by a friend and local club member after he posted a pic on Facebook - his friend saw it and they got to talking and put him together with me, the rest is history as they say.

He's already home in Texas and drove Buzz to the store!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 12, 2016, 01:31:52 PM
Buzz's new owner reports that he's having a ball with him, he reports that everywhere he goes he gets waves and thumbs up, and he's really enjoying the car, I'm happy to say.....

Title: Re: 1980 Clubman Estate
Post by: 94touring on March 12, 2016, 02:28:18 PM
That's awesome.  His hand is even on a newly matched wing lol.  The guys at the paint store last week were asking about it.
Title: Re: 1980 Clubman Estate
Post by: Willie_B on March 12, 2016, 03:31:23 PM
Well glad i got to ride in it when I did then.
Title: Re: 1980 Clubman Estate
Post by: John Gervais on March 12, 2016, 03:40:25 PM
Awesome that with 5 MINIs behind him, he'll get to really appreciate their heritage first-hand.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 12, 2016, 05:16:16 PM
Yep, Buzz is the first Mini he's ever driven - said he rode in a few when looking to buy but the owners wouldn't let him drive!

He's a happy owner so far!
Title: Re: 1980 Clubman Estate
Post by: towjoe on March 12, 2016, 06:47:51 PM
A nice way to sell a car.
Something I have been thinking about. I think BAT would be a good place to list mine.

Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 12, 2016, 07:46:59 PM
BaT has been getting some strong money, especially on Minis and Jags......
Title: Re: 1980 Clubman Estate
Post by: MiniDave on March 27, 2016, 11:20:53 AM
Buzz's first Texas car show, since he moved to the warmer climate....in City Park, Kilgore Texas..... bet he was the only Mini there!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 10, 2016, 11:29:03 AM
Justin wrote this weekend.....

I am just so Proud of this little guy. We just did over 300 miles around East TX and he just purred the whole way. Goal was to simulate an average rally day. Doing the math, he averaged 37 mpg. He does have a couple of namesake "Buzzs" I hope to get addressed before this summer's rally. With each passing day I am feeling more confident he will be my ride for ‪#‎MTTS2016‬. Kudos to Dave Craven for getting him sorted out to the point he did before I adopted him.

Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 10, 2016, 11:33:48 AM
Another pic from the run yesterday, a little place just outside of town where Buzz lives..... ;D
Title: Re: 1980 Clubman Estate
Post by: 94touring on April 10, 2016, 11:43:29 AM
Is that his house?
Title: Re: 1980 Clubman Estate
Post by: Willie_B on April 10, 2016, 12:38:32 PM
I will be at the start and do the first days drive of MTTS 2016. I will be on the lookout for them.
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 10, 2016, 04:53:58 PM
Quote from: 94touring on April 10, 2016, 11:43:29 AM
Is that his house?

No, I didn't write that sentence quite right..... ;D ;D

Justin and his partner's firm is doing the interior design......

Another pic from the run yesterday, a little place just outside of the town where Buzz lives.....
Title: Re: 1980 Clubman Estate
Post by: MiniDave on April 10, 2016, 04:55:36 PM
Quote from: Willie_B on April 10, 2016, 12:38:32 PM
I will be at the start and do the first days drive of MTTS 2016. I will be on the lookout for them.

It will be fun having some classic's in the mix, even for a short time.....I was planning to drive Buzz to Sandy Eggo this summer, but across the whole US twice - 11,000 miles?  In the summer?  I don't think I could do that.....
Title: Re: 1980 Clubman Estate
Post by: 94touring on April 10, 2016, 05:06:45 PM
I was about to say if that's his house you didn't ask enough money!
Title: Re: 1980 Clubman Estate
Post by: MiniDave on December 26, 2017, 01:53:34 PM
A small postscript to the tale of Buzz......

Buzz was named by my wife, as I was driving him home from Baltimore to KC, at one part she called me and of course had a lot of trouble hearing me over the cacophony of noises - she named him Buzz on the spot!

Today I was wandering around the net and came across Dooder's website, one page has pics of people from all over the world wearing his shirts, and as I was looking at the names and faces, one stuck out.....a fellow by the name of John is sitting in the back of a beige Estate, named Pudwell. John Davis is the fellow who imported Buzz, and Terry Pudwell was the man who owned Buzz last in England....had I known Terry's last name when I bought Buzz I might have named him Pudwell too!

Here's the pic, apparently before Buzz got his new paintjob and stripes......it is a small world indeed, especially where Minis are concerned!
Title: Re: 1980 Clubman Estate
Post by: Willie_B on December 26, 2017, 02:18:55 PM
Cool.