keep it up Rick nice work!

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Good day in the garage after 2 days off....

Welded in replacement front parcel shelf...and...welded up all of the holes from the roof rack install more than 35 years ago.  We used 2" wide, 18 gauge, side to side strips to allow plug welding of the holes in the roof.

On to the new wings & apron with the original bonnet tomorrow!

(IF we keep adding steel I may soon be unable to pick up the shell)

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One outer sill to install when it goes through the shrinker later this week - it was a 6 flute Hadrian panel converted to 4 flute and rearced.  Other wise the Mini is upright for front clip fitment and scuttle closing panels...so wings, slam panel and original bonnet.

Today we finished up the lower back end, located the fuel tank and rear subbie to see if we could improve on the standard rear arch closing panel...I think we managed it.

I also took a close look at the A Pillar welds and decided we would cut out the 'doorside' splices and weld in 20 gauge...both sides.

I'm tempted to toss my van on a trailer and send it to Rick to weld up !

My 1973 OZ Mini Window Van has the stressed toof and no headliner behind the two seats up front.  Empty it has a tinny sound...loaded nada.

Ahah! Some Mini problems take longer to figure out... though 44 years may be a new record.

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Got a bit done today and rear valence assembly ready to be welded on after primer & paint in the to be hidden area has set up.

Most important was to provide a more robust location for the lower latch pin on the rear barn door.  Because the hole in the floor originally had a thick washer spot welded around the hole but had a bigger hole, the latch pin ovalled the hole in the floor over time...so new thick washer with 3/8" nut drilled out to 25/64" and welded into the thick washer at the correct angle.

Yes Dan, they went to the stressed/ribbed roof to remove the vibration/wobbling that produced the drumming sound.  i hope that the steel cross strops will end that while also allowing us to weld up the roof rack holes with less risk of warping.  We'll use cold wet towels and air flow over the welding area to help too.  

Rick: can you explain the "roof flexing/wobbling at speed"?

My first Mini was a Mk1 Counryman. Above about 40mph it would get a faint constant-pitch droning sound (something like a Landcaster bomber in the distance) that I never figured out. Some kind of harmonic thing going on. I tried replacing tires, rear wheel bearings exhaust etc. to no avail and the car drove straight and had no tire wear problems, so it did not seem to be an alignment issue or engine/drvietrain exhaust harmonic. I wonder if it was the roof....

NO roof rack.  Yes Spitz, we will be welding up the holes to steel strips crossing the roof side to side.  Should help dissapate the heat and also address the roof flexing/wobbling at speed....

Looking good....looking warm!   Was -30 here this morning.  Wish I could be working on my Van.

Are you refitting a roof rack or welding up those holes?

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Both full length doorsteps and new inner & outer A Panels are welded in.  2nd outer sill is being shrunk to recurve after we hammered out the 6 flutes and pute 4 flutes in as per MK I.

Got on with repairs at the rear yesterday after addressing exposed weld in the left hand A Pillar.

Interesting that the rear wheel arches did not appear the same length...you will see in photos after remnant closing panels were removed.

Arches repaired, 2nd rear corner repaired, closing panel on the completed RH outer sill welded in at rear.

And I have a complete set of door hinges after looking in parts bin for a #1/#2 half.  no bushes worn through.

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Thanks Dan!  My steel bashing & welding partner and I are looking to create a sound car.

Should finish up doortep & A panels intall today on the right hand side.  Later a few smaller repairs at the rear and new closing panels & valance.  Then the nose, new wings, early MK I apron and hopefully the original bonnet.  One door needs modest skin work right at the lower hinge location (rust between the reinforcing bracket & skin).

Son has convinced me to put 1293cc build into the Woody & Turbo into the Aussie Van which has 8.4" discs.  Alex has persuaded me to go with 10" wheels on the Woody so Cooper S brakes....

It's coming.  Lots more to do!

Today's photos from yesterday are entitled - Poof, Bam, Pow...and MAGIC happens!

Rick... some of the infill repair sections you are doing are beginning to look "Project Binky"ish. Nice work.

Two questions:

1. When will the videos be coming out?
2. Once you get the body sorted, what all-wheel drive system are you going to install?

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Liking it...so am I!

Got after the righthand full length doorstep install today...the Hadrian panel was another 1/8th inch longer than the lefthand piece we shortened.

All prepped, sized, ready for welding...Tremclad in the cavity between the sills (will Waxoyl the cavities after paint).  Weld through primer on the bare steel before spot, plug & seam welds tomorrow.

Also melted the lead on the A Pillar welds to see what was underneath and weld as needed, worked on the door (it had S trim at one point)...moving along.

On to fitting the inner & outer A panels after doorstep install. 

I keep looking for the Like button! I'm enjoying watching this resurrection build, Rick.

But it's making me feel guilty for letting myself get talked into cutting up the remains of the 67 Elf I picked up a few years back.

John got on a roll after I left last night and got the a panels welded in...looking more like a Mini!

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Lost 3 days (Tues-Thurs) as my steel massaging partner was ill.  Back at it yesterday.  Slow progress fitting the doorstep, aligning the door, the inner/outer A panels.

Hadrian full length doorstep panel was 1/8" too long.  Needed to make a cut and weld up.  But doorstep in with seam & spot welds.  Where seam welded on the rear quarter the upper steel was flanged to receive the new doorstep. 

A panels bolted together to locate the inner, tack weld, unbolt & weld up....

While John was fussing with steel alone, I blasted more bits...found one brass hinge amongst the side door set when the Orange was blasted away.  All pairs were there #1/#2. #3/#4, #5/#6, #7/#8.  They need a little work - remove broken bolts, check pins etc.