Mk 1 Project Zippy. Looking Like a Car.

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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby fozzza » Wed Feb 03, 2021 10:39 pm

So sorry to hear that Dave.

Kind regards Roy
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby dusz » Fri Feb 05, 2021 12:05 am

Family comes first.
Take care of yourselves.
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sat Feb 20, 2021 6:41 pm

Many thanks to all who have left messages, PMs and texted kind thoughts. It has been very much appreciated. Dad is doing ok and has been insistent that we sort all the shelves and shelves of stuff that Mum collected over the years. It's keeping him busy whilst we wait for the funeral.

One thing I was never 100% happy with was having fixed 1.5 degree negative camber bottom arms on the front as there is no room for adjustment. Some came up on the Mini Forum at a decent price and once various lockdown issues were sorted, payment was made and they arrived on my doorstep. Thanks Pete! All the adjusting threads were clean and serviceable, just the outward appearance was slightly tarnished (as expected). Not a problem. Have bench grinder with wire wheel, will use it. I split the arms into their component parts and gave everything a good going over on the wheel, removing the tiny bits of surface rust and general grubbiness.

Once done, I masked up the threads and gave the newly keyed surface a coat of the same blue that the rest of the suspension components have. Once dry, I will reassemble them and put them on to the car and remove the old ones.

As purchased.

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Cleaned up, masked and...

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...painted.

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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sun Feb 28, 2021 5:37 pm

I can't lie. I came perilously close to coating the car in petrol and torching it today. I have been having a LOT of trouble with the exhaust and it clearing the gear selector. Extending the pipe was done which was fine - it moved the bend in the front pipe past the body of the selector which was fine - exactly as planned. Unfortunately the problem is not now with the length of the pipe (said the actress to the Bishop) but the angle of the dangle. The selector itself is sitting slightly angled towards the driver's side, and this small issue is preventing the exhaust from sitting right, as well as making the selector hang a touch low. This is a remote tunnel with a rod selector, so nothing fits correctly, and my modified bracket doesn't make everything line up correctly.

I have therefore bitten the bullet and have ordered a bracket from Mini Spares. I am also going to make tentative enquiries into getting a Maniflow exhaust system made up.

I know I should choose my battles but it seems that everything on this car is fighting me right now, and the lack of assistance from car-minded friends due to covid plus my recent news about Mum has put me at an all-time low with this bleeping car. If it was a normal car, I would have been able to bolt everything back together relatively easily. Instead nearly everything is bespoke and has to be amended or remade. I do not have the ability to be able to just knock things up on the lathe (not that I have one).

Seriously considering knocking it on the head.
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby fozzza » Mon Mar 01, 2021 8:54 pm

Hi Dave, don't give up now, you have put a hell of a lot of work into your project.
I do understand where you are coming from though. On paper these are simple basic cars to work on, but in practice quite the opposite, especially trying to fit modified or self made parts. It is the nature of the beast, its almost as if you have to earn the cars respect before it will allow you to have any fun. Believe me it is worth it, I love my Mk2, perhaps that's why I'm a glutton for punishment and took on my Mk3 project, which like yourself is giving me a shed load of problems.
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby dusz » Wed Mar 03, 2021 11:55 pm

Hi Dave
I was hoping that once you had finished your Mk1 and that the COVID restrictions had been lifted that you would come and help me recommission my Mk2. I am not far from the Mendlesham Mast.

As far as I remember my original exhaust manifold cracked at the point where the outer two pipes join, this was back in around 1993 ish. I purchased a replacement stainless steel LCB manifold from Minimine in Staffordshire as at the time one of the owners worked where I worked and they were considerably cheaper than Mini Sport etc. If I recall I didn't have any issue with the manifold lining up with the system or clashing with the gear linkage (rod type) although it is rather awkward to get everything in place if you are working alone and on your back on the floor. My exhaust exits to the right of centre at the rear.

I don't know how much difference there is between the Mk1 and Mk2 floor pans. Hope you manage to get it sorted.
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sat Mar 06, 2021 9:56 pm

I have been completely blown away by all the support I've had recently. This forum and the others I am on are full of like-minded people who have problems with what they're doing too. Everyone's kind words and encouragement has rejuvenated me. If I could I would bring a couple of crates of beer and just say "help yourselves". I think that the "knocking it on the head" rant I had last weekend has done me the world of good. I've had a long think about what I have achieved and that little set-backs ALWAYS have a solution. Just for the record though, I will NOT be rushing to get this finished in time for the 10th anniversary of me getting it. I'd rather do it properly. Jeremy, when we can, I'd be happy to pop down the A14 and 140 to give you a hand.

Which brings me on to my next update, and it IS a better one. I have re-attached the gear selector properly, and has made quite a difference. I jumped on to the Mini Spares website as they do have a bracket to attach a rod change selector to a remote change tunnel (which is much more "rounded" for those that don't know). I had initially rejected the bracket due to its cost and made my own (it was out of stock back then), but as I am working from home and not commuting at the moment, I bought one and had it DHL'd to my eager waiting palms.

First thing I noticed when getting the bracket out of the packet was that it didn't quite line up. That was a really easy fix - a gentle tap with Clyde the Club Hammer saw everything brought back in line. The second thing I realised was just how much smaller the bracket was in comparison to the one I'd made. Yes, I'd used the bigger cotton reel mounts on mine, but there was quite a significant difference. This would really help with fixing the issues with exhaust clearance. The new bracket is also angled to the rear of the car, so new holes needed drilling. But I am not that untidy - I spent some time filling in the old holes so I wouldn't get road spray when it rains.

I then lined up the bracket having attached it to the bottom of the selector, made some marks and drilled some holes. I bolted up the brackets first then slotted the bolt through the selector. I then made sure that I could easily select all gears. SUCCESS! In the words of a guy called Tony who used to work on my Mini back in the 90s: "Well I ain't takin' that f***er off again!" There is SO much more room there for an exhaust now. Very pleased.

I am now waiting to hear back from Maniflow as I also shot them an e-mail last Sunday. I expect that they're on a skeleton staff at the moment. I will chase it up in a couple of weeks.

Difference in brackets quite substantial.

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Holes filled in

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Nuts have appeared and are holding stuff in place!

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And doesn't it look neat all tucked up there!

Image
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby dusz » Sat Mar 06, 2021 10:58 pm

Hi Dave
Great to see you have made some progress but you haven't painted it blue. So are you going to take it off to paint it? :D :D
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Mon Mar 29, 2021 4:55 pm

Tempting - but I would need to key it all to make the paint stick. I will revisit it at a later point.

This update has no specific photographs. However, I will treat you lovely people to couple of images. I recently had a birthday. I asked for some contributions to the Zippy fund - and I have had some generous donations. Thank you family!

Therefore I picked up this:

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flashed this (ouch!)

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and in a few weeks will have a delivery from these guys

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Sadly the guy I spoke to wasn't called Barry but the super helpful David was brilliant. This has put my mind at rest. Excellent.
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sun Apr 11, 2021 3:52 pm

I haven't posted much in a while as it's been a bit of a rubbish Easter. One of our cats, Moneypenny, had a spinal stroke and we've been ferrying her to and from specialist vets and now we've got her home we're having to do a lot for her. It hasn't been the best of times. She is now home, which is great, but progress is slow and it will take a long time for her to regain the use of her right legs. Daily physio and massage will help, and at least we can do that!

So I give you the world's smallest update. When I was doing my thing with Minis in the late 90s there was a guy in the club who turned up gear knobs on his lathe. I have acquired one of these (Tink had it in his garage) but the original insert for it to screw to the gear stick was missing. Instead there was a much larger hole. I asked a few knowledgeable people and the suggestion was to fill it with epoxy and either tap it or put a nut in there with the correct thread. Epoxy I can do!. So I quickly mixed it up and chucked it in. Drilling and application of the appropriate nut will follow.

I will be out of action for a couple of weeks as I need to have a minor operation next week (day surgery, nothing serious) so will be back on things when I feel more up to it.

Miss Moneypenny in happier times

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Wooden gear knob I want to use. It will be tidied up before use.

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Big hole where there was once an insert.

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So I filled it up with epoxy. Drilling and other shenanigans will follow.

Image
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