Mini Restoration Manual

Filled with everything restorers are looking for including Mini history, buying information, specs, bodywork, mechanics, interiors, electrics, mods, tools, color schemes, clubs and more. Clear, step-by-step photographs and instructions make this the book for renovating your bodywork and interiors, giving new life to mechanical and electrical components, plus improved performance and appearance. Covers all models including Mini Cooper. Strongly recommended. For those who love Minis, or are thinking about buying.

Lindsay Porter has written more than 50 how-to books and well over 1000 practical articles for magazines on motoring, caravanning and other subjects. His first piece of professional writing was in 1979, for DIY (Do It Yourself) Magazine, explaining how he and wife Shan built and extended their own country cottage - the cottage they still live in today. Even then, their house was designed (by Lindsay) and built to the highest standards of insulation and sustainability.

contents

Foreword

4

(1)

Paddy Hopkirk

Introduction & Acknowledgements

5

(1)

Using this book

6

(1)

Heritage

Mini Make-up

7

(2)

Man Behind The Mini

9

(1)

Mini Roots

10

(1)

Launch and Development

11

(1)

Quirks and Cocktails

12

(1)

Production Notes

13

(1)

Mini-Coopers

13

(3)

Edwardes and on . . .

16

(8)

Buying

Take Your Pick

24

(2)

Where to Look

26

(1)

Making Sure

27

(1)

Stage A -- First Impressions

27

(1)

Stage B -- Clean Hands

28

(3)

Stage C -- Dirty Hands!

31

(1)

Minis put under the microscope

32

(5)

Buying -- in conclusion

37

(1)

`Agreed Value' insurance

38

(7)

The `Easy Restoration'

45

(32)

Restoring Bodywork

45

(6)

Engine Overhaul, Engine Bay and Brakes

51

(12)

Gearbox Rebuild

63

(6)

Finishing Off

69

(8)

Bodywork

77

(104)

Mini -- the ideal restorer's car!

77

(1)

Equipment

77

(4)

Tool Box

81

(1)

Stripdown and examination

81

(11)

Fuel tank removal

92

(3)

Bonnet removal

95

(1)

Front wing removal

95

(5)

Windscreen and rear screen removal and refitting

100

(4)

Windscreen rail repair

104

(7)

Front door hinge pillar repair

111

(1)

A-Panel repair

112

(2)

Front panel renewal and modification

114

(3)

Flitch panel renewal

117

(2)

Door stripping, removal and refitting

119

(6)

Adjusting bonnet, boot lid and Traveller rear doors

125

(4)

Door skin renewal

129

(5)

Sill (inner and outer) repair

134

(7)

Quarter panel (rear side) replacement

141

(2)

Battery box repair

143

(1)

Boot hinge panel repair

144

(2)

Front subframe removal

146

(3)

Rear subframe renewal

149

(3)

Rear subframe temporary repair

152

(1)

Rear apron renewal

153

(2)

Door sliding glass channel renewal

155

(3)

`Woodie' Traveller woodwork renewal and Estate side window removal and refitting

158

(1)

Roof rail repairs and scrapyard body parts in general

159

(2)

Leading body seams and lead loading

161

(2)

Respraying

163

(9)

Fitting up

172

(3)

Rustproofing

175

(2)

Roof aerial -- fitting

177

(4)

Interior

181

(8)

Trim removal and trim general

181

(7)

Headlining removal and refitting

188

(1)

Mechanical Components

189

(64)

Suspension and brakes (general) and depressurising Hydrolastic systems

189

(2)

Brakes and suspension (rear) -- dismantling

191

(5)

Brakes and suspension (front) -- dismantling

196

(7)

Master cylinder renewal and fitting new seals

203

(3)

Brake pressure failure warning light actuator -- overhaul

206

(1)

Brake lines

206

(4)

Bleeding the brake hydraulic system

210

(2)

Engine/gearbox removal

212

(9)

Engine strip

221

(2)

Clutch removal

223

(19)

Engine/gearbox refitting

242

(7)

Clutch change with engine in car

249

(1)

Carburettor strip

250

(3)

Electrical Components

253

(6)

Wiring and wiring loom general

253

(2)

Lighting circuit trouble shooting

255

(1)

Wire size selection

255

(1)

Distributor overhaul

255

(3)

Horn general

258

(1)

Modifications

259

(61)

Buying a second-hand engine

259

(1)

Which engine to transplant?

260

(1)

Clues to engine identification

260

(1)

Priority modifications for engine performance

261

(1)

Swapping heads? Caution!

262

(1)

Gearbox and final drive ratios

262

(1)

Cooling system

262

(1)

Fitting an alternator/Negative earth conversion

262

(1)

Brakes, suspension and wheels

263

(3)

Accessories -- general

266

(7)

Appendices

Workshop Procedures and Safety First

273

(5)

Tools and Working Facilities

278

(3)

Specifications

281

(7)

Production Modifications

288

(5)

Colour Schemes

293

(26)

Clubs and Specialists

319

(1)

British and American Technical Terms

320

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Mini Restoration Manual

Summary

Author Biography

Table of Contents

Supplemental Materials