Time lapse full metal Broadspeed GT restoration/transformation

[Dr.Mabo]

Today is international labour day. But unfortunately in times of global lock down. So I think it’s a pretty good moment to start sharing my actual long-term labour project with you.

All my long-term Mini projects took a time period of more or less nine years each. These was usually caused by changing circumstances and personal situations. In 2015, as my last project was about to be finished, the idea of my next project was born. I wanted to focus on something more challenging rather than just restoring another Mini.

I always fancied the Broadspeed GT. But with the remaining number of only a hand full of original Broadspeeds, the chances to find and acquire an original wouldn’t be realistic. And from the craftsman’s point of view, I don’t like the idea of material change within a single flat surface (rear side panel: half metal / half glassfibre). Thus, I decided to build my own full metal Broadspeed GT. But this of course needs some good preparation and planning. The first years I basically spend with researching details. Before, I was only playing with the various parts of the different Minis versions, particularly the early ones. Now, the possible parts range immediately extended to various British cars of the late 60th. Especially cars I had never heard of.

On the other hand I needed to extend my personal skills. Shaping metal into a particular form is something totally different then exchanging rotten body sections with available replacement panels. As an aircraft engineer by trade, I was only taught the metal basics. After a while I found an academy in Germany, which train classic car restoration skills including various metal shaping classes.

To use the new skills, I also needed the appropriate tools. Okay, If you know how to tailor and have the scissors, you are not automatically a fancy new fashion designer. To become that, I needed to create my own cutting pattern and mugs.

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Than it was time to find a good Mini. In the beginning I had a Cooper S MK1 in mind, to be as close as possible to the original. But due to the rarity of those Minis and to keep costs low, I decided an ordinary MK2 would do the job nicely. Just external door hinges are a must. I found a 68’ MK2 body shell on wheels that was of the road since the mid 80th. Before I could start with the transformation into a Broadspeed I had to start with the regular restoration work.

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First step was to visualize the idea with photoshop. The surf blue Broadspeed photo is currently a simulation but will be reality in the near future. This helps a lot when motivation disappears due to excessive body works or other backstrokes.

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So long
the Doc

[GraemeC]

This will be interesting. Looking forward to the posts.

And it'll the source of much skill and workshop envy!!!

[timmy201]

Love the "Broadspeed Body Shaper"!

[phil82]

Thumbs up. Good stuff!!
Cheers Philipp

[harrymini]

Great project, looking forward to the progress

[InnoCooperExport]

Should be good, looking forward to seeing this develop.

[Catmint]

Looking forward to this

[morris-miner]

I'll be following this with great interest.

[UHR850]

Jip me to, great project.

Kees

[burchy35]

Cracking looking workshop . I will also be following this project for inspiration.

[Andrew1967]

This is going to be a great project thread

[Dr.Mabo]

Thank you all for your interest so far.

At first, the Mini had to be dismantled to the bare shell. Even when there was not much mechanic left, axles, steering and suspension had to get of the Mini. Surprisingly after more than 30 years in storage the Hydrolastik was still working fine without leakage. The shell was basically solid but oversills have never been a good choice, not even 30 years ago.

Before storage the shell has undergone some restoration and got a color change from green to white. Obviously was never reassembled. But storage time wasn’t as quiet as for other cars. The Mini has been flooded once up to the waistline. It didn’t make to much damage but since then dried mud stuck in every corner. Thus every hollow space has to be opened and cleaned. I have removed tons of hard mud. Another impact was on the roof. Some kids where climbing onto the roof so there are several huge dents. But with the idea of modifying the roof anyway it should be possible to solve this problem too.

so long
the Doc

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[mk1]

Thanks for the post Doc, this is one I am looking forward to following!

[Dr.Mabo]

Now the regular restoration work starts. Time for the wings was over anyway. Now I took the front panel off. It was in a quite good state except the area behind the bumper lip. But I wanted to keep the front panel. A-pillar was half way rotten, but the inner wings were fine. So I build a repair section just for the A-pillar.

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Radiator shroud removed and holes closed. Also on the other side all unused holes closed and some se

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ctional repairs at the edges. I try to keep good metal and only change the rotten parts.

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Sill and lower doorstep removed too. These are the first new panels I will install.

so long
the Doc

[Dr.Mabo]

I ordered a bunch of body panels. Due to one or two panels out of stock I had to wait about 4 month for delivery. In the meantime I started with the panels, which I bought from another supplier. The left lower doorstep was the first. Although the shape was okay it was a little to short. The positions of the radiuses were not correct. So I cut it in two and added a little metal stripe. All was welded together and grinded out.

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so long
the Doc

[AndyPen]

Impressive workmanship - always a joy to watch developments like these

[roger mcnab]

hi doc what was holding this poor little car together what ever it was will be rectified with all this good work going on and good luck with this under taking
cheers roger mcnab

[Catmint]

Do you have the article about Church Green from a mini mag in the 90's? - a couple of very interesting pictures about how they went about it. If not I can post it up

[roger mcnab]

hi doc
how do you think you would go at making it all steel a good chance with the good gear at your hand it would be a challenge but would solve joining problems with grp and would be nice and strong
just a thought
cheers roger mcnab

[Dr.Mabo]

Do you have the article about Church Green from a mini mag in the 90's? - a couple of very interesting pictures about how they went about it. If not I can post it up

Hi Catmint, thanks for the hint. Yes I have the article of Chruch Green. The secret basically is to find the correct shape and to build the right bucks were necessary.

how do you think you would go at making it all steel a good chance with the good gear at your hand it would be a challenge but would solve joining problems with grp and would be nice and strong

Hi Roger,
good gear is always usefull. But the havy and powerfull gear is pretty expensive. I have seen skilled people forming a 1 to 1 bobycar only with a mallet on a tree stump and some simple tools. So it is possible. It is just a matter of skills and time. And this is my personel challenge. Developing my skills step by step and panel by panel.

so long
the Doc