Mk 2 Rebuild (to replace the company car)

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Mk 2 Rebuild (to replace the company car)

Postby Kadmandu » Sun Jun 16, 2019 11:09 pm

Hi All

Well, after looking for a new shell for the last couple of years for my rather tired Mini...... i came across a complete (minus engine) Midas Mk 2.

After wallowing around in the company car for the last few years ive bitten the bullet and decided to go back to what i love - simple mechanics & a car to just drive and enjoy. The midas will be a daily car so its a full rebuild for reliability etc.

After a very late night pickup from scotland (from a lovely mini and Marcos enthusiast) where a wheel nearly fell off the trailer (....4 wheels on trailer - remove 2...sorted) my new project landed in Yorkshire:

ImageScreenshot_20190529-124933 by Timothy Ordway, on Flickr

The interior wasnt too rotten to a good sign that not too much water had gotten in:

ImageIMG_20190608_170206 by Timothy Ordway, on Flickr

Rear beam doesnt look too bad ...yet (more investigation etc) and it came with some new-ish spare shocks to replace the rather rusty ones:

ImageScreenshot_20190529-125151 by Timothy Ordway, on Flickr

Ant the front end was clearly refurbished with adjustable ties etc in the last few years:

ImageScreenshot_20190529-125114 by Timothy Ordway, on Flickr

So - i set about the great strip and after reading the build manual (rather sparse) and scouring the forum for a few hours i had a good idea of how she came apart - 4 hours later:

ImageDSC_0031 by Timothy Ordway, on Flickr

ImageDSC_0034 by Timothy Ordway, on Flickr

Minor bump damage found in repaired bumper and compression cracks to the main body behind on gelcoat filled in previously:

ImageDSC_0039 by Timothy Ordway, on Flickr

So now its the endless sanding, filling, sanding exercise for prep to paint (by somone with 2K ability due to their being small gelcoat cracking all over etc).

i have to say - while its nice to have no rust.... gelcoat and fibreglass takes a bit of learning, firstly ive learned that:

1. where possible sand back to gelcoat after guide coating (fills minor scratches).
2. Using a crosshatch pattern seems to be a good way of sanding (60 - 140 - 500 grit).
3. where the gelcoat has deep cracks - dremel is your friend to gouge out the gelcoat and use epoxy filler (im using a classic west system for boats).
4. there are LOTS of curves...... which takes ages to get a good finish.
5. do all sanding by hand in block style where possible so as not to burn through the gelcoat.
6. the gelcoat is very thick and very tough!
7. Its exhausting lol.

So here are a few photos of where im up to after about 20h work.

Resin repairs to do to subframe bolt:

ImageDSC_0046 by Timothy Ordway, on Flickr

Back quarter dust coating - stopping filler to minor cracks & general sanding:

ImageDSC_0044 by Timothy Ordway, on Flickr

Those rear gills take some fiddly sanding!

ImageDSC_0045 by Timothy Ordway, on Flickr

Cracks to gelcoat dremel out ready for epoxy filler:

ImageDSC_0043 by Timothy Ordway, on Flickr

Engine Bay in progress:

ImageDSC_0047 by Timothy Ordway, on Flickr

Wiper posts completely corroded = next purchase a dremel

ImageDSC_0027 by Timothy Ordway, on Flickr

Pushed her out into the sunshine..... just to keep some inspiration (quickly followed by dash back in due to rain lol).

ImageDSC_0042 by Timothy Ordway, on Flickr

All my daughter said is "its even smaller than my car dad" lol

ImageDSC_0041 by Timothy Ordway, on Flickr

Some rather poor historic repair work to the bulkhead due to heat damage - not sure if its a remove and repair job yet as the resin and matt is rather thick! i was going to install an aluminium heat shield over anyway so might be just a tidy up job.

ImageDSC_0048 by Timothy Ordway, on Flickr

And "George" my ever faithful friend - sits in the garage watching me, he seems excited (which is more than i can say for my daughter lol).

ImageDSC_0050 by Timothy Ordway, on Flickr

So all in all, after the strip i can see i will be calling on Alastair's help for door seals, trim's, window seals etc but most of what i need is all there or in my donor.

The only parts i'm struggling to source (or repair) are:

1. The front fibreglass headlining was missing - any idea where to get one or what else to use? i have the rear lining around the boot.
2. Carpets - they look like cleverly stitched up items with vinyl trims etc - has anyone got patterns or a supplier whos done these before?
3 - Front lights - allegro metal frames utterly rotten - none on ebay and wondered if anyone has had any luck with using standard kit car suppliers - the bulb size is fine, its more the plastic angle adjuster frame etc that the issue.
4 - Rear beam - anyone still making the new uprated units ive seen from a few years ago on the forum?
5 - Wiring diagram - I think mine was an MG Metro (red lines on the speedo binnacle) but having no luck finding a decent pinout etc.
6. Any advice gratefully received re sanding, prep & painting (this is my weakest area).

Anyway, i shall try to keep the posts coming with a 16 week plan for rebuild (huge parts pack order ready to go for Huddersfield MiniSpares).

Oh - and if there is anyone near to Huddersfield with a Mk 2 id love to be able to pop over just to see what it should look like and connect with fellow enthusiasts etc (and catch a lift to the Oldham run if possible).

Tim
Machines are designed to be used.....so get out there and enjoy :-)
Kadmandu
 
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Re: Mk 2 Rebuild (to replace the company car)

Postby fozzza » Mon Jun 17, 2019 2:55 pm

It's good to see another Midas under restoration. The MK1/2 doesn't offer much headroom especially if you have a long torso. If I was you I wouldn't bother about obtaining a fibreglass roof linning and just cover it with a material.
As for the Allegro headlights, if you are keeping it original then Rimmer Bros sell the complete units including frames but they are not cheap.
I wish you well with your project.
Roy
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Re: Mk 2 Rebuild (to replace the company car)

Postby Stuart » Mon Jun 17, 2019 7:39 pm

Another option for headlights if none turn up.

viewtopic.php?f=53&t=2956&hilit=mk2+headlights
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Re: Mk 2 Rebuild (to replace the company car)

Postby Kadmandu » Mon Jun 17, 2019 11:09 pm

Hi Fozza

Youre right, its quite height limited & will have to replace the CRX seats it came with (some period buckets should be fine) and lucky im a short-arse lol

I will have a go with either gray type carpet (similar to the stuff the young types wrap their boom boxes in) or have a tinker with a vinyl solution. There is an aftermarket sunroof so i suspected the original headlining wouldnt be an option etc.

Good Idea with Rimmer bros - not too worried about price etc, more future repair and reliability as this will be my main daily car.

Hi Stuart

Thank you, i cant believe i missed that post on the forum - some good ideas there!

The back plates are plastic and the front capture plate is fine - its just the chrome capture trim around the actual light unit thats rusted - i might be able to get creative with some carbon fibre time depending but have no idea what was used on mine - definately not allegro units!
Machines are designed to be used.....so get out there and enjoy :-)
Kadmandu
 
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Location: Halifax, West yorkshire

Re: Mk 2 Rebuild (to replace the company car)

Postby MrBounce » Tue Jun 18, 2019 5:45 pm

Reminds me how far mine has come since I ripped it to bits and got the Dremel out...

Image
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Re: Mk 2 Rebuild (to replace the company car)

Postby Kadmandu » Wed Jun 19, 2019 8:42 pm

Oh my days bounce! .... That is some serious gelcoat work! You've actually given me the best encouragement I could have as mine is no way as much hard work as that! I just need to keep the sanding up...every night....my hand moves on its own in my sleep now I've done so much blocking lol. How does the car look now, hope the repairs have gone well. Any gelcoat/ repair advice you can give would be gratefully received.
Machines are designed to be used.....so get out there and enjoy :-)
Kadmandu
 
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Location: Halifax, West yorkshire

Re: Mk 2 Rebuild (to replace the company car)

Postby DavidL » Thu Jun 20, 2019 12:12 am

The car's dashboard was designed for a Metro instrument pod, but it doesn't use a Metro wiring harness. The wiring harness is unique to the Midas, or so I was told.
Having said that, I'd imagine you could modify a Metro wiring harness to fit.
If you're using a 6 volt coil from a Metro, the standard Midas wiring harness will need to have a ballast resistor fitted.
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Re: Mk 2 Rebuild (to replace the company car)

Postby Kadmandu » Fri Jun 21, 2019 8:02 am

Hi David

That's great thanks, that explains it, I've rebuilt mini's and a metro and I was getting confused that it's not fully recognisable as either..... A special lol. I don't suppose anyone's tried to map it out in a wiring diagram?

Mr bounce
I just found project zippy.... Looking great and you really have come far... Well done!
Machines are designed to be used.....so get out there and enjoy :-)
Kadmandu
 
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Location: Halifax, West yorkshire

Re: Mk 2 Rebuild (to replace the company car)

Postby Kadmandu » Tue Jun 25, 2019 10:19 pm

So i thought id keep the update going .... if only to have an honest log of what goes into a full rebuild.

Ive seen a few "i took it to the sprayer" type makeovers which doesnt really demonstrate the amount of effort required to do all the repairs, fill cracks, flat coating, sanding, priming, sanding, pinhole filling, sanding (you get the drift).

Well im starting to curse the historic owner who painted the car black in cellulose,, this has not only poorly bonded requiring complete sanding back to gelcoat (i manage about 20cm2 / night) but this seems to have created a heat stress effect with micro crazing all over the car gelcoat etc.

Ho hum......on with the sanding

So ive performed the resin repairs to the front crossmember as the main update and been working around the car:

ImageDSC_0054 by Timothy Ordway, on Flickr
Front crossmember nearly there & marking wiring

ImageDSC_0059 by Timothy Ordway, on Flickr
Micro cracks show up clearly with dust coat.....more repairs

ImageDSC_0055 by Timothy Ordway, on Flickr
stress cracks in door scuttle/ pocket

ImageDSC_0056 by Timothy Ordway, on Flickr
Minor repairs to do to the NS sill, looks to be just the gelcoat but will sand back as far as i dare & resin mat repair.

ImageDSC_0058 by Timothy Ordway, on Flickr
Its all these compound curves that takes care and time to sand back the old paint to.

ImageDSC_0057 by Timothy Ordway, on Flickr
Decided to block back to the rear quarter panel and look at more permanent repairs to the microcracking all over the panel

ImageDSC_0053 by Timothy Ordway, on Flickr
One of my favorite angles......sanded sills

ImageDSC_0052 by Timothy Ordway, on Flickr
Getting there.....just all the compound angles on the front valance left.....then its onto the next 2 phases of progressively finer sanding.

ImageDSC_0060 by Timothy Ordway, on Flickr
Wiring loom marked up and removed - looks like there are only a few repairs required & could identify all but 4 or 5 wires.... im sure it will make sense going back together eek

The bad news is that after receiving quotes form local sprayers the cost was expected to be in the thousands so i suspect i will have to become a Jawel non-isocyanate 2k paint specialist........and do it myself so if anyone has any advice with using their paints or a low volume/low pressure setup it would be gratefully received.

Oh, the good news is the rear beam looks to be in even better nic than i expected.....to the previous owner who coated it in oil......i thank you.

Thats all for today.......tank removal tomorrow (looks terminal) but i suspect a minivan stainless steel one would be a good idea as its to be my daily driver (peace of mind etc).
Machines are designed to be used.....so get out there and enjoy :-)
Kadmandu
 
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Re: Mk 2 Rebuild (to replace the company car)

Postby fozzza » Thu Jun 27, 2019 1:30 pm

Regarding a wiring diagram, if you go on to the Midas Owners Club website and click on downloads, the fourth one down gives you all the drawings for the Bronze.
Roy
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