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This is one fascinating thread.

Some more rust removal necessary before the shell can be sand blasted. Repair panel forming is also a good training for later body shaping tasks and Broadspeed transformation.


Its just gaswelded. No grinding necessary.


so long
the Doc

The shell came back from sand blasting. I’m pretty confident the shell is rustfree now and the fun can begin. Unfortunately with the sand blasting some more areas show up with the need of new metal. First I thought the spare wheel bowl would be in a good shape. But it proved me wrong. Lots of little pinholes appeared while the shell was outside in the sun (marked red). Not a good base to weld every hole. So I decided to change just the bowl section. Here we go.
so long
the Doc

Doc,

This project just gets better & better!

I am totally in awe of your skills.

Thanks Mark

As long as I can turn the shell in every position I need, without a rotordip, I want to finish all tasks on the floor section. Therefore I use a roof rack with wheels and some wood laths, screwed to the floor. That allows me to turn the shell on the side and on the roof by my own, without the risk of damaging any panel. But the roof rack needs rain gutters and they will be gone soon. So good planning is essential for all the tasks.

I had removed the inner cross member to remove all sand, mud and rust. After sand blasting it came back in. But I usually install it the other way around with the seat mounts on the rear. And that’s what I did here as well. Particularly for the Broadspeed its useful, due to the lowered roof and the necessity to install the seats in a lower and more rear position. Its easy with the early round tunnel, as the cross member has symmetrical shape. I also removed the seat belt stiffener for the same reason. And it came back again.
The battery box was shot anyway, so a new one came in. I’m totally happy with a Magnum box. The shape is okay, even in detail. I just had to cut it down a little on the wheel well side, because it was too high. I also reshaped the tongues for the battery fixing bar which don’t have the right shape. But these were easy tasks. So there is no need to go for the more expensive BMH bat box.
So long
the Doc

Every time I log into the forum, the first place I go at the moment is to have a look at this thread.

Quality of your work is briljant!

mk1 wrote: ↑Mon Jun 15, 2020 8:31 am Every time I log into the forum, the first place I go at the moment is to have a look at this thread.

Me too Mark!

It's just mindblowing how good you work Dr.

Stunning work. I'm looking forward to follow the build

If you need another fix before the next instalment, type this into youtube... "Peter Tommasini Shaping Monaro Quarter Panel".

I know why I have no skill .. some other b^&$er has it all

Cheers, Ian

Blimey that is quite impressive isn't it?
I wouldn't know where to start.

Thanks, I have seen this before.
It is absolutely impressive how this one piece quarter panel was made.
To get to this kind of skills is a long long way. I'm just a beginner, so my panels are a lot smaller Maybe thats why my welding skill are developing

so long
the Doc

It’s always good to know who is the brainchild of a project. This is one reason why I decided to sign my work. The other reason is to avoid that this Broadspeed becomes a fake and could be called original at some point. The signature should be prominent, largely not removable but not visible on the first sight. So the best place for that is the boot floor extension. The Broadspeed uses the regular Mini rear valance but has an extended tail like a Hornet or Elf. The hand embossed signature stiffened the panel and it’s only visible from below or with a mirror

so long
the Doc

Briliant well done.

Kees.

Even your signature is gorgeous.

hi doc it is reassuring to see some one else that has to walk sideways in their shed but with saw bench and 3 motor bikes and a mazda car ride on mower etc 70 square meters is not very big
nice work
even less room with the unipower on the bench
cheers roger mcnab

Wonderful work and amazing skills!!

Is it your job??

Charlynsane wrote: ↑Thu Jun 18, 2020 12:57 pm Is it your job??

No, its just for my personal amusement.
I'm aircraft engineer and working in the quality department.

so long
the Doc

Now its time finish the last up side down tasks. Rear valance and the two rear valance closing assemblies. All are from Magnum and again I’m happy with them. The closing assemblies only needed a little bend to follow the boot floor. Years ago I saw cheap rear valances with a wrongly curved lower edge. This was basically visible when you are in the car behind the Mini. But nowadays they have the correct shape and I couldn’t find any drawback with this one. That’s why I gave them a try and I’m not disappointed.
It’s just a hassle to get rid of the factory paint. But paint stripper is working fine. It’s just a little mess with handling and cleaning. I prefer my yellow anti corrosion Etch Primer, which bites into the metal and is a good base for later painting. In closed areas an additional layer of regular primer plus Mike Sanders anti corrosion grease should protect the areas for the next few years. I also installed a ventilation hole on each side for the same reason as they are in the sills.

so long
the Doc