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Pixel-Snapper
3,514 posts
61 months
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Like the sound of the frontend, I'm planning on having a metal removable front end and have been looking at mounting and bracket ideas recently.
Be interested to see how you get one with that.
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RussellG
Original Poster
489 posts
54 months
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I will take plenty of pictures when it comes to making the front end up and making it all work. I have an old fibreglass flip front that I intend to experiment with so that I can get the hinge and the locking mechanism working correctly then I will make up a metal front.
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RussellG
Original Poster
489 posts
54 months
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Hinges arrived today so hopefully i can get some time to get the door skins done this weekend and then get cracked on with making the hinges fit and work.  10/1/12 by russell.grant, on Flickr
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Fatboy
7,282 posts
141 months
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I've had the same plan for my flip-front - except I was going to use E39 BMW boot hinges - mainly because there was an E39 in the scrappy when I went hunting, so the hinges are now sat in my garage  Looks cracking - I really must get my act together and crack on!
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RussellG
Original Poster
489 posts
54 months
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I would guess probably almost any Modern saloon car hinges could be used in reality. Like you I choose e46 ones as they were available cheap online and I could check size and how they moved on my own car.
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RussellG
Original Poster
489 posts
54 months
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RussellG
Original Poster
489 posts
54 months
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Todays updates Finished the top of the ns inner wing from yesterday  15/1/12.1 by russell.grant, on Flickr Then went back to the door, cut out the bulk of the rot on the nearside one  15/1/12.2 by russell.grant, on Flickr  15/1/12.3 by russell.grant, on Flickr Then time to replace the missing metal and dress it all off  15/1/12.4 by russell.grant, on Flickr  15/1/12.5 by russell.grant, on Flickr A quick dusting of primer and thats the nearside door fixed just to fit the door skin now  15/1/12.6 by russell.grant, on Flickr  15/1/12.7 by russell.grant, on Flickr It was at this point that the diesel heater in the garage decided to stop working so I wasted a couple of hours today stripping it down and getting it working again. I did eventually get round to starting to fit the door skin. I have managed to position it correctly and weld it in place at the top. I just need to fold the rest of the skin over the frame to finish this door. Pictures of this will follow soon. Should hopefully manage a couple of nights in the garage this week to finish that and start the other door
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Pixel-Snapper
3,514 posts
61 months
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Top stuff Russell.
I plan to get some top coat on the bulkhead after work tonight.
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RussellG
Original Poster
489 posts
54 months
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Pixel-Snapper said: Top stuff Russell.
I plan to get some top coat on the bulkhead after work tonight. You will need to get some pictures up. I might go out for a while and finish the door skin.
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Pixel-Snapper
3,514 posts
61 months
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RussellG
Original Poster
489 posts
54 months
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Done a bit more work tonight  17/1/12.1 by russell.grant, on Flickr  17/1/12.2 by russell.grant, on Flickr Door skins on now just needs a bit of fine tuning and an a panel fitted, you cant tell from the pictures but the panel gaps look ok so far
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RussellG
Original Poster
489 posts
54 months
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Havent had anymore than a few hours on the mini since the last batch of pictures. Works halted on the ns now till the new hinge screws are delivered, then I can get back to fitting the door and A-panel up correctly. Until then I decided to make a start on the os door. First thing I noticed when lifting it up onto the workbench was that its a bit heavier than I remember any mini doors being but the next couple of pictures should explain why  30.1.12.1 by russell.grant, on Flickr  30.1.12.6 by russell.grant, on Flickr I quick survey of the rest of the door reveals the usual rusty areas(although not as bad as the other door was) and the section the upper hinge is fitted to badly twisted and cracked. Which probably explains why someone has done a botch job of the old door skin with tons of filler.  30.1.12.2 by russell.grant, on Flickr  30.1.12.3 by russell.grant, on Flickr  30.1.12.4 by russell.grant, on Flickr  30.1.12.5 by russell.grant, on Flickr  30.1.12.7 by russell.grant, on Flickr Managed to straighten up the damage, made a start to welding up the cracks and dressed them as I went along  30.1.12.8 by russell.grant, on Flickr  30.1.12.9 by russell.grant, on Flickr Bit more work to do yet on it but thats for another night
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JC T ONE
122 posts
62 months
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Well done  keep up the good work -
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RussellG
Original Poster
489 posts
54 months
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A few hours work this afternoon. Started by finish of the frame repairs to the offside door  4/2/12.1 by russell.grant, on Flickr  4/2/12.2 by russell.grant, on Flickr  4/2/12.3 by russell.grant, on Flickr Then for a change of scenery I went back to the nearside and added an A-panel.  4/2/12.4 by russell.grant, on Flickr Fairly happy with the fit so far just needs a bit of fine tuning and dressing off the welds. Time for a well deserved trip to the pub. Might try a bit more tomorrow once the hangover passes
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RussellG
Original Poster
489 posts
54 months
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Well a hangover & a trip to the apple store to have my phone replaced stopped me working on the mini this morning. However I did manage to get a few hours in this afternoon. Welds all dressed off on nearside and im happy with the panel gap on the door leading edge too  5/2/12.1 by russell.grant, on Flickr  5/2/12.2 by russell.grant, on Flickr The trailing edge of the door is going to need a bit more work but I will do this once I have the offside at the same stage.  5/2/12.3 by russell.grant, on Flickr I have the offside door skin fitted as well, still needs a few welds dressing off on the underside but not much.  5/2/12.4 by russell.grant, on Flickr Im quite pleased with the progress this weekend but the offside A-panel and flitch look like they will need a fair bit of tweaking to make it all line up well. Hopefully get onto this next time.
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Pixel-Snapper
3,514 posts
61 months
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Coming on well russell.
Gap looks good at the front. Will you add metal to the rear to bring it in line?
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RussellG
Original Poster
489 posts
54 months
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Yeah thats exactly what im planning on doing. I will probably spot weld the metal in while the doors still fitted. Then remove the door and weld it up properly.
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RussellG
Original Poster
489 posts
54 months
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Not much to show for tonights few hours. Got the door skin on the offside finished & tested fitted door. the door is a fairly good fit but the A-panel wasnt going to be a great fit on the offside, so rather than mess around I decided to measure up then remove the door and cut the edge of the flitch. After which I ground down the flitch to give me the correct position for the A-panel. I have now tacked the edge of the flitch back in position.  7/2/12.1 by russell.grant, on Flickr  7/2/12.2 by russell.grant, on Flickr  7/2/12.3 by russell.grant, on Flickr Next time I wil grind the tacks flat then refit the door and test fit the A-panel fit again. Hopefully after that I can remove the door and weld it all back up properly.
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RussellG
Original Poster
489 posts
54 months
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Minor update tonight. Finished modifying the flitch & I am now half way through fitting the A-panel. I only spent a couple of hours at it tonight but it should mean hopefully I will get time to alter the door trailing edges to give the desired gaps.  9/2/12.1 by russell.grant, on Flickr  9/2/12.2 by russell.grant, on Flickr
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miniman
16,012 posts
131 months
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Hadn't seen this thread until now, fantastic project!
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