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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Mar 15, 2011 8:01 pm 
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Joined: Thu Dec 09, 2010 2:47 pm
Posts: 179
Whats your location?: Sandyford, Dublin
Region: Eastern
What Minis have you?: Matte black Leyland Mini Clubman 1380cc.
Location: Dublin
This looks like a savage mini!! Hope it all goes well for you!! And all that dedication will pay off for you!!
Hope to see it out and about!!

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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Mar 15, 2011 8:06 pm 
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Joined: Mon May 09, 2005 12:49 pm
Posts: 4549
Whats your location?: Ballyhooly, North Cork
Region: Southern
What Minis have you?: 1967 Morris Cooper, 1967 Austin Mini auto, 1968 Wolseley Hornet x2, 1981 Clubman Estate
Location: Ballyhooly North Cork
KMG is internet-less at the moment but hopefully has been working away in the garage. There should be loads of progress to report on soon.

Billy


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Mar 15, 2011 11:07 pm 
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Joined: Tue Jul 18, 2006 11:15 pm
Posts: 2075
Whats your location?: Dún Laoghaire, Dublin
Region: Eastern
What Minis have you?: '93 SPi cooper
Location: Dún Laoghaire, Dublin
Billy wrote:
KMG is internet-less at the moment but hopefully has been working away in the garage. There should be loads of progress to report on soon.Billy
could that be described as InterNought?

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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 6:26 am 
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Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
What with other things on the go it has been a while since I updated progress withn the GT.I had to sort out the exhaust and I am using a maniflow system so I needed to join the Suzuki outlet to the Maniflow.I got the long pipe from the Suzuki which started out looking like this.
Image
By putting the Maniflow in place and offering up the link pipe I reckoned I needed the back part of the pipe so I cut that off
Image
And I was left with this bit
Image
I also needed the flange from the other bit so I cut that off and I had to file out the old piece of pipe from the inside of the flange.You can see in this photo the old pipe is still inside the flange.
Image
I had to widen the Maniflow pipe to get the link pipe into it so I cut a couple of short slots to cut the link pipe to fit in.
Image
Once I was happy with the way it fitted underneath the car and was well clear of the gear linkage I welded it up.
Image
Because the link pipe was originally flared at the flange I needed to enlarge it to fill in the gap so again I cut lots of slots at the end and flared it out and with the exhaust in position I tacked the flange in place,removed it from the car and welded it up.
Image
Here is the finished item
Image
And I decided to give it a coat of green Hammerite to match the back box section.
Image

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 6:37 am 
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Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
I have also been working on getting the MAF sensor mounted.I originally wanted to position it near the front of the car to cut down on induction noise but I have decided to mount it up near the bulkhead until I get the car running.I took a K&N filter I had for a HIF44 and cut the back to fit the MAF.
Image
I then got some cork gasket and marked out a gasket for the sensor.
Image
Here is the sensor with the air filter on.
Image
And here is where it will sit in the engine bay for the time being.
Image
I also welded plates over the brake hose holders on the subframe and drilled out smaller hoses as I will be making my own Aeroquip hoses.
Image
I will be sending the subframe out for powder coating this week.

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 8:45 am 
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Joined: Tue Jul 18, 2006 11:15 pm
Posts: 2075
Whats your location?: Dún Laoghaire, Dublin
Region: Eastern
What Minis have you?: '93 SPi cooper
Location: Dún Laoghaire, Dublin
kerryminigringo wrote:
What with other things on the go it has been a while since I updated progress withn the GT.I had to sort out the exhaust and I am using a maniflow system so I needed to join the Suzuki outlet to the Maniflow.....
thats going to be nice 'n loud!

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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 9:15 am 
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Joined: Mon Jan 15, 2007 12:41 am
Posts: 1085
Whats your location?: Carrick on shannon
Region: Western
What Minis have you?: 1980 mini saloon (fip) 1275cc
1969 Clubman gt historic rally car, 1380 c/r s/c dog box, split 45 webbers
1980 irish clubman estate
1969 mk2 retro rally car 1293 s/c gearbox
Location: roscommon
Very nice work Aidan, i have the same problem with the exhaust manifold, but i was looking last night, u can buy a pipe expander for 26 euro, it allows the u to expand one pipe to let the other side into it, seems to be a neat job


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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 9:55 pm 
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Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
This is what the subframe and engine brackets looked like Monday evening.
Image
And this is what I collected from the powder coaters today.
Image
I blanked off the tower bolt threads with a couple of old bolts and washers.
Image
And when I removed them I had nice clean threads.
Image
I ran a tap through the holes for the top arm holding plate and I may have to run a round file around the top arm holes to remove the powder coating but after that it is ready for brake lines and fitting.

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 10:17 pm 
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Joined: Mon Jun 15, 2009 1:20 pm
Posts: 837
Whats your location?: cavan
Region: Western
What Minis have you?: 1996 BRG mayfair 1275 auto-lyin up now
1990 1l city-daily driver
1993 cooper spi-completly stripped and upside down!
the long term project(advantage) courtesy of mr skelly!!
rotten shell-found a floor repair panel in the boot tho!
great work as always, that subframe looks great

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 Post subject: Re: 1275GTi conversion
PostPosted: Thu Apr 28, 2011 11:40 pm 
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Joined: Mon Sep 14, 2009 8:34 pm
Posts: 1516
Whats your location?: knockbine
tullycanna
ballymitty
co. wexford.
Region: Eastern
What Minis have you?: 1972 pick up
1979 leyland
88 designer
Location: south east region
thats a nice lookin inlet manifold :wink: :wink:

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................................FOUNDER OF HILLBILLY ENGINEERING.................................
FROM THIS TO THISImage


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 Post subject: Re: 1275GTi conversion
PostPosted: Mon Aug 08, 2011 9:18 pm 
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IMOC Paid Member

Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
I suppose through lack of motivation I have not done much to the GTi lately but I have been doing little bits and pieces and now seeing as Maxi has his on the road I better get a move on.I had made a template for the inner wing to allow the alternator access and I marked up the inner wing.
Image
Using a combination of jigsaw and nibbler I cut out the hole in the inner wing to allow the alternator through.I have a plan as to how to make up the cover so I will get working on that in the next couple of days.
Image
I started work on the front brake hoses and I used Aeroquip hoses forall the front hoses.I had welded tabs onto the subframe for the one that goes to the passenger side and I also used pipe clamps to fix the fuel pipes in place.
Image
I used a T-piece to connect the front pipes together and used more pipe clamps to tidy things up at the drivers side of the engine compartment.
Image
I used bulkhead fittings to get the pipes into the pedal box.
Image
Image

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Mon Aug 08, 2011 9:39 pm 
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IMOC Paid Member

Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
I got in contact with John Staunton of JOMO engineering and he said he would get the drive shafts sorted for me.I gave him the measurements and he cut the shafts to lenght allowing for the joint.He took one side down on the lathe and put a hole in the other piece of the shaft.As is was designed to be an interference fit he had to use a combination of heat and a press to force the two pieces together.Then were then TIG welded to allow for twisting and the weld was cleaned up after on the lathe.I forgot to take pictures before I primed them but here they are.
Image


Image
As I have a great big pedal box in the way I cannot get fresh air to the heater at that side so I have to bring it in the other side so I took one early heater(because I want both pipes at the passenger side) and dismantled it.
Image
A crude but effective way of testing the heater matrix with a lenght of hose,a bolt a couple of jubilee clips and an air gun.
Image
I drilled out the spot welds holding the air intake at the drivers side.
Image
And I mounted the motor in its place and tacked the intake to where the motor used to be.New foam on the inside and a lick of paint and it is ready for fitting.Not sure how effective the fan will be but I suppose I will find out.
Image
I also ran the hoses to the pedal box from the bulkhead fittings.I need to make a bracket to mount the reservoirs in the engine compartment.
Image
I finished the wiring of the toggle switches and it took 3 relays to do what the hazard switch normally does although one of those is just for the LED.Woody had a way of doing it using a switch only but this was not available in toggle form.
Image
At present the engine if fitted and connected to the rad and exhaust and I will be fitting the suspension and moving towards getting the ECU connected.

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Aug 09, 2011 10:55 am 
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Joined: Tue Jul 18, 2006 11:15 pm
Posts: 2075
Whats your location?: Dún Laoghaire, Dublin
Region: Eastern
What Minis have you?: '93 SPi cooper
Location: Dún Laoghaire, Dublin
:) nice work.....

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Image Signature awaiting top-coat and lacquer....


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Aug 09, 2011 12:48 pm 
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Joined: Tue Mar 24, 2009 7:40 pm
Posts: 2244
Whats your location?: South Dublin
Region: Eastern
What Minis have you?: 1995 Mini Mayfair
1994 Mini Sprite
kerryminigringo wrote:
At present the engine if fitted and connected to the rad and exhaust and I will be fitting the suspension and moving towards getting the ECU connected.


GO GO GO!!!!!!! :lol: Epic work, can't wait to see this car! :D

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StanO'Toole :mrgreen:


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Aug 09, 2011 1:19 pm 
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Joined: Sun Mar 28, 2010 4:23 pm
Posts: 235
Whats your location?: West Cork
Region: Southern
What Minis have you?: 1983 Mini City E
Beautiful work KMG. The car will be a real credit to you when it's on the road. All the best with the rest of it. :)


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 Post subject: Re: 1275GTi conversion
PostPosted: Fri Aug 12, 2011 7:20 am 
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Joined: Fri Oct 23, 2009 8:59 pm
Posts: 1076
Whats your location?: Leopardstown
Region: Eastern
What Minis have you?: 86 Mayfair 1000GT
Modifications: 1275 and bar the shell and subframes new everything!! IMOC MEMBER
Location: Leopardstown
As always very nice work Mr pres :D

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ALL YOU NEED IS POWER AND LOADS OF IT!!!


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 Post subject: Re: 1275GTi conversion
PostPosted: Fri Sep 09, 2011 10:12 pm 
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Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
Alternator mounted and wired up.
Image
I needed to make an enclosure for the alternator so I got a piece of aluminium wire and bent in into the shape of the opening of the inner wing.I used it to mark out a piece of sheet steel which I would use for the lid of the box and then I welded a strip of metal around the top to form the box.I then used the aluminium template to mark out the contour of the enclosure and I welded a strip arounf the base and welded a couple of threaded section onto it so that I could bolt it onto the inner wing.
Aluminium wire template.
Image
Top of enclosure cut out.
Image
Top with side welded on.
Image
Finished item awaiting cleanup and paint.
Image
Suspension on and brakes plumbed.
Image
I needed a way to join the battery cable along with the stater feed,alternator charge cable and fuse box supply cable so I mounted a busbar insulator on the cross member and ran all the calbe to that point.It will make it handy if I have to jump start it as I will have a boot board fitted.
Image
I have the rad hoses connected but I will look into getting custom ones made after I get it running so that I can get rid of all the jubilee clips.I also mounted the expansion tank on the inner wing,this came from a 98 Honda Accord.
Image

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Fri Sep 09, 2011 11:57 pm 
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Joined: Tue Jul 18, 2006 11:15 pm
Posts: 2075
Whats your location?: Dún Laoghaire, Dublin
Region: Eastern
What Minis have you?: '93 SPi cooper
Location: Dún Laoghaire, Dublin
really nice work there... . its coming along very well.

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Image Signature awaiting top-coat and lacquer....


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 Post subject: Re: 1275GTi conversion
PostPosted: Sun Sep 11, 2011 9:28 am 
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Joined: Fri Dec 05, 2008 11:44 pm
Posts: 1324
Whats your location?: Dublin
Region: Eastern
What Minis have you?: 1992 Mini City
Location: Lucan
MTM2012....no pressure!! :wink: :wink:


Tony


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 Post subject: Re: 1275GTi conversion
PostPosted: Sun Sep 11, 2011 8:05 pm 
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Joined: Mon Feb 07, 2005 1:42 pm
Posts: 198
Location: Neverland
great stuff aidan, really cant wait till you have it on the road so we can compare notes :)

presently im 75% deaf and have a fuel bill bigger than the 'northwestern'. but im told this
is just part of the running in process.

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 Post subject: Re: 1275GTi conversion
PostPosted: Mon Sep 12, 2011 5:32 pm 
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Joined: Tue Sep 23, 2008 5:12 pm
Posts: 587
kerryminigringo wrote:

I needed a way to join the battery cable along with the stater feed,alternator charge cable and fuse box supply cable so I mounted a busbar insulator on the cross member and ran all the calbe to that point.It will make it handy if I have to jump start it as I will have a boot board fitted.
Image


Would that be a safety issue there in the event of a short? With its proximity to the fuel lines?


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Sep 13, 2011 5:03 pm 
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Joined: Thu Feb 10, 2005 9:44 pm
Posts: 2676
Whats your location?: Between an A series and a G13B
Region: Eastern
What Minis have you?: 60 Austin Se7en
61 van,68 MKII,
75 Clubman estate,
80 1275GT
91 RSP Cooper
Location: Between an A series and a G13B
All the terminals where covered with heat shrink and when the build is finished I will be putting thread-lock on the connecting bolt.I will also be making a cover to protect against accidental shorts and anyway when I put a right hand tank in it there will be 5.5 gallons of fuel basically sitting over the battery so if I was to worry about shorts it is there that I would be worried about. :D And the photo does not show that the insulator is about 60mm further out from the fuel lines.

_________________
Real Clubmans have a square nose.Seriously.


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Sep 13, 2011 8:43 pm 
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Joined: Fri Feb 11, 2005 9:01 am
Posts: 517
Whats your location?: Maynooth
Region: Eastern
What Minis have you?: 1962 - Morris Traveller MK1 - 1978 - 1275GT, 1998 - Sportspack
Location: Maynooth - Kildare
Aidan,

why don't you use duck tape?

You would have had the car on the road by now.


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 Post subject: Re: 1275GTi conversion
PostPosted: Tue Sep 13, 2011 10:56 pm 
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Joined: Tue Jul 18, 2006 11:15 pm
Posts: 2075
Whats your location?: Dún Laoghaire, Dublin
Region: Eastern
What Minis have you?: '93 SPi cooper
Location: Dún Laoghaire, Dublin
zakgt wrote:
Aidan,

why don't you use duck tape?

You would have had the car on the road by now.

yea Aidan, dont'cha know it would be quacker?

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 Post subject: Re: 1275GTi conversion
PostPosted: Wed Sep 14, 2011 2:12 pm 
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Joined: Tue Sep 23, 2008 5:12 pm
Posts: 587
kerryminigringo wrote:
All the terminals where covered with heat shrink and when the build is finished I will be putting thread-lock on the connecting bolt.I will also be making a cover to protect against accidental shorts and anyway when I put a right hand tank in it there will be 5.5 gallons of fuel basically sitting over the battery so if I was to worry about shorts it is there that I would be worried about. :D And the photo does not show that the insulator is about 60mm further out from the fuel lines.


Ah right! Id still be fairly worried about that in the event of a crash, are you using a inertia switch too? How did you mount the return line? Is it returning into the R/H tank and the supply coming from the L/H? You going to use a swirl pot design and two pumps or just the single pump?


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