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  Author    Marcos 8042 Build  (currently 2,426 views)
Mike_Smith
Posted on: March 16th, 2022, 22:59:23 Quote Report to Moderator
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Let me introduce myself. I am located in Victoria BC and have been involved with Minis here in Canada since the 70's. I have owned about 15 or so..

I lose count over the years, and have had sedans, late and early one, including an older Cooper, a Moke, a Van, A Mini GTM Coupe and now I am building up a Mini Marcos kit from 1974. The kit has been bouncing around from owner to owner with the best of intentions on getting built, but it has not happened.  

The current owner of this kit, Iain, has had it for about 15 years, and approached me to build the car for him. So here I am starting to pull it all together with a pile of donor parts in boxes and a shell with the usual Marcos bits. When it is drivable it will go back to Iain for the finishing touches.  

I will post my progress and ask a bunch of questions on how it all goes together. The instructions are very general, so there are some areas I am not really sure how they go together.  Thanks in advance for any help.  Mike

Mike in Victoria BC - building 8042

Last modified March 16th, 2022, 23:04:31 by Mike_Smith
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Mike_Smith
Posted on: March 16th, 2022, 23:05:56
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Here is the Body Shell getting ready for the build

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: March 16th, 2022, 23:07:36
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and boxes of bits.. soon to find there way on or in the car...

Mike in Victoria BC - building 8042

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mike brown
Posted on: March 16th, 2022, 23:16:45 Quote Report to Moderator
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Welcome, Looks like it doesn't need much to get it running. I suspect the interior will be the longest job.
Mike
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Mike_Smith
Posted on: March 16th, 2022, 23:32:56 Quote Report to Moderator
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unfortunately it has nothing on the sub frames that is usable as sitting for so long all the rubber has perished and the metal bits have rusted, so first order of the day is getting suspension and braking sorted. That means new cones, all rubber parts, brakes, brake hoses and lines, brake cylinders, discs,shoes,  brake lines ball joints, tie rod ends..etc.. Next up will be figuring out the mounting of all the parts on the firewall area, so I can put the engine and front sub frame in.. it will keep me busy for a while!  

Mike in Victoria BC - building 8042
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Mike_Smith
Posted on: March 17th, 2022, 18:04:18 Quote Report to Moderator
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A couple of questions I have..

1. How does the heater mount to the firewall? Do I have to fabricate a bracket to use the two rods on either side of the heater box. I am using a MK3 heater box.

2. The steering column is mounted to the underside of the fiberglass dash tray, but it seems inadequate to support it even with a steel plate on the topside of the try. Any suggestions for an additional mounting method?

3. For the door seals, is it best to use MK1/2 style or the MK 3 door seals with the rubber bulb on them?

4. for mounting the wiper motor, was there a bracket supplied to mount inside on the dash tray?

Thanks.. Mike

Mike in Victoria BC - building 8042
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mike brown
Posted on: March 18th, 2022, 18:41:22 Quote Report to Moderator
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Yes you will need to make some brackets for the heater.
The steering column is normally just bolted through the lower rail of the dash, yes a spreader plate is required. I have in the past had to add some fibreglass reinforcement to this area.
Door seals I've bought from a car trim company and picked the size and shape that best suited the gap.
From memory the wiper motor mounts on the bump in the bulkhead (opposite your chassis plate). Normally on the engine bay side then passing through the bulkhead to the wheelbox holes but I have seen them mounted inside the dash to.
Mike
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Mike_Smith
Posted on: March 19th, 2022, 17:35:13 Quote Report to Moderator
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Thanks Mike, I appreciate the information. Is there a usual way to mount seat belts in the car, as there seems to be no provision for this with any mounting points in the car body.

Mike in Victoria BC - building 8042

Last modified March 19th, 2022, 17:36:34 by Mike_Smith
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mike brown
Posted on: March 19th, 2022, 21:26:55 Quote Report to Moderator
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Some cars had mounts on the tunnel, B post and sill they were just metal plates with a captive nut glassed in place. However some had nothing, if there isn't any the normal practice is to fit a large spreader plate on the outside and bolt through the body and plate. Obviously this wouldn't be very good on the B pillar so most fit harnesses and mount the shoulder straps through the rear floor just in front of the fuel tank.
Mike
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Mike_Smith
Posted on: March 20th, 2022, 17:55:17 Quote Report to Moderator
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There appears to be nothing on this body, so will end up glassing in some steel plates with captive nuts then.  I have to build some floor mounting bases for the seats, so I may tie that into the belt mounts at the front as well. Lots to think about. Thanks again.

Mike in Victoria BC - building 8042
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mike brown
Posted on: March 21st, 2022, 19:53:49 Quote Report to Moderator
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If you go for harnesses you can pick up on the rear subframe but you'll need to make some brackets, bare in mind the subframe is rubber mounted.
Mike
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Mike_Smith
Posted on: March 22nd, 2022, 20:05:09 Quote Report to Moderator
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I do have a set of belts already which has one strap heading to the back, so was thinking making a bracket picking up the front sub frame mounting bolts for the rear sub frame and also the floor area . Thanks for the suggestion.

The other Mike

Mike in Victoria BC - building 8042
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Mike_Smith
Posted on: March 23rd, 2022, 00:07:12 Quote Report to Moderator
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Another question... How do sun visors mount to the car.  The headlining is already installed on the car from when it was first delivered, and I can't seem to find any spot where a mounting block may have been added under the headlining.    

Mike in Victoria BC - building 8042
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mike brown
Posted on: March 23rd, 2022, 20:52:45 Quote Report to Moderator
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Some cars had a strip glassed in across the roof, some had four blocks and some had nothing. All three options are obvious, if you have blocks or a strip short screws work fine. If you have nothing your options are limited personally I've never bothered with them but I'm 6'3" so sun visors are pointless for me. The other option is to either peel back the headlining and glue some blocks in or cut the headlining out where you want the block, upolster the block and glue it to the roof where your cut out is.
Mike
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Mike_Smith
Posted on: March 24th, 2022, 00:56:59 Quote Report to Moderator
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Quoted from mike brown, posted March 23rd, 2022, 20:52:45 at here
Some cars had a strip glassed in across the roof, some had four blocks and some had nothing. All three options are obvious, if you have blocks or a strip short screws work fine. If you have nothing your options are limited personally I've never bothered with them but I'm 6'3" so sun visors are pointless for me. The other option is to either peel back the headlining and glue some blocks in or cut the headlining out where you want the block, upolster the block and glue it to the roof where your cut out is.
Mike



Thanks Mike.. might just skip the visors.


Mike in Victoria BC - building 8042
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Mike_Smith
Posted on: March 31st, 2022, 02:09:25
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Got the rear sub frame rebuilt, all new bits.. suspension and braking.. and brake lines run..  now onto the fronts.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: March 31st, 2022, 02:10:24
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Brakes done

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: March 31st, 2022, 02:11:38
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Other side.. using some Minifin brake drums

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 3rd, 2022, 18:54:27
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Moving onto the front subframe, , rebuilt with new cones, adjustable trumpets, brake hose and lines, wheel bearings, ball joints, tie rod ends and new CVs. Waiting on new brake discs, so I can then install the new pads as well.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 3rd, 2022, 18:55:32
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A fitting of the engine into the front subframe so I can offer it up to the car to see how the weber carb will fit.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 3rd, 2022, 18:56:58
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And lowered the body over the engine and subframe using the hoist.. nice and easy to get it in that way!

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 3rd, 2022, 18:57:58
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It looks like I can get away with not modifying the firewall and fitting the car with the pancake filter...

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 12th, 2022, 19:44:50
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I have the pedal box all mounted up. I had to modify the lower bolts fastenings as they ended up hanging in mid air rather than against the firewall. I also fabricated an extension to the end of the pedal bracket so I could provide more support for the column.   The throttle cable sits in a brake fitting bolted through the firewall, drilled out enough to hole the end of the cable.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 12th, 2022, 19:46:11
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I was not happy with using two drop brackets for the column so made a single one welded together..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 12th, 2022, 19:48:56
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Next I fabricated two brackets to hold the heater assembly.. each bar goes across the opening in the center of the dash area and provides mounting points similar to how they are in the Mini.  The heater is help up on the two back rods, and two screws up front. Undo the screws and the heater will swing down.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: April 12th, 2022, 19:50:29
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Heater brackets on the car..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:37:54
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Heater box and defroster vents now installed and access holes for defroster tubes cut.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:38:57
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Defroster

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Mike_Smith
Posted on: May 5th, 2022, 18:39:33
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Radiator mount modified to lower the rad by 1 inch..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:42:49
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Work started on the wiring harness. This is a Luca Uniloom from Premier Wiring. Very well made, but no connectors come with the kit. I have added the standard bullet connectors for the lighting and scavenged other harnesses for the rest of the connectors.

The harness is getting laid out in the car to adjust the lengths of the wiring and then will be wrapped and tidied up.  The dash is getting a sub harness so it can be removed easily later if required. The back lights are also on a sub harness I built.  

The harness comes with pretty comprehensive ground wiring, but as the car is fiberglass I have added additional grounding wires so that very device has a ground wire directly to it.

Mike in Victoria BC - building 8042


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Mike_Smith
Posted on: May 5th, 2022, 18:47:00
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The dash sub harness

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:49:22
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More harness work getting all the connectors on the wire ends. The car is using later model column switches for the start, wipers, horn signal and hi/lo beam .  Dash switches will be for the headlamps and park lamps, and the 4 way flashers.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:50:28
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Trial fit in the car with the dash.. I am keeping the fuses inside the car to keep the engine firewall cleaner looking.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:52:36
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The wiper motor is also mounted inside the car.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:54:20
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Starting to sort out the engine side of the harness.  All the switches and lights have been tested and seem to work OK.. 4 ways not working as waiting on a switch to come from the UK

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: May 5th, 2022, 18:55:51
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Got the seats mounted today, and the lap belt portion of the seat belts.. next is to locate the rear seat belt strap and figure out how to anchor them.  The seats are early Miata seats, which I have slightly raised the front mounts to give a better sitting angle. They have a very large range for front and back movement, so good to adjust for different sized drivers.

Mike in Victoria BC - building 8042


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Graham Bichard
Posted on: May 7th, 2022, 18:20:13 Quote Report to Moderator
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Mike, can I ask that you expand on how you raised the front of the seat subframes?
This is something I think I'll need to do (eventually) for a more comfortable seating position.
Car's coming along nicely by the way.
Cheers,
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Mike_Smith
Posted on: May 10th, 2022, 17:49:38 Quote Report to Moderator
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Graham, I used some 3/4 inch X 3 inch rectangular tube, cut a section the width of the Miata front mount, one for each side. I then drilled through, small hole on bottom for bolt, larger hole on top so the lip on the underside of the Miata mounting tab fit into the top hole. Then it was all bolted through with longer bolts.  I'll grab a picture when I remove them for painting..  Mike

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:21:09
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Graham, here is what I used to raise the front on the Miata seats.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:22:23
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Another view. Top hole is large enough to center the dimple on the Miata seat bracket. The lower one is sized for the mounting bolt.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:24:07
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Pulled the doors off as there was rust seeping from under the hinges. I will clean these up, repaint the hinges and install with new bolts and nuts.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:24:48
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Hinges cleaned up and ready for painting

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:26:33
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Door buffed to remove the rust stains..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:28:36
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Small AGM battery mounted in rear on passenger side as this is a LH drive car. Battery cables are run inside up into the dash area and passed through the firewall using brass studs and nuts.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:29:24
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Cables running up into the firewall from the battery.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:29:59
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Wiring harness wrapped and ready for final installation

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:33:30
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Pretty much all the firewall holes have been drilled for wires, throttle, speedo, choke etc... with the fiberglass so much thicker than a typical steel mini firewall, I had to find grommets to accommodate the thickness. and in some cases grind carefully around the hole so the grommet would fit.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:34:54
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The fuse box and the turn signal/4 way flasher hides in the glovebox area.. to be covered up with a small glove box container.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:35:29
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The glovebox interior...

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:36:04
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And the secret door to find the fuse box!

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:38:05
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Wiring harness all fitted, hooked up and tested on the car. Ran into one strange issue as LH rear signal lamp would come on with the Park lights.. eventually found a short in the front LH turn signal lamp housing. All goo now.  Dash now fitted to the car as well as the top dash pad and rear view mirror.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:40:29
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The small front panel on the nose is not being installed on the car, so I am building a grill which covers the hole between the hood and the body of the car. It's made from some generic ABS grill panels material and will be removable with 2 small bolts.

Even the interior light works.. you can see the door switches in the picture. For now as the doors are off the battery will be disconnected.

Mike in Victoria BC - building 8042


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Mike_Smith
Posted on: June 15th, 2022, 02:42:09
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A close up of the grill in the opening..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:42:35
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And a shot from farther back..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:43:39
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Drive shafts rebuilt with new CVs, all new boots and greased up..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:44:29
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All cleaned up, painted and reassembled. Ready to install on the subframe and engine.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:45:12
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And installed....

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:45:56
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Brake pads installed for the 7.5 inch disc brakes..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:47:15
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Heater connected for defrosters, and heater cable installed under the dash on a bracket, rather than on the wood dash..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:50:08
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I attempted to install the engine and sub frame so I could get everything else attached, but ran into difficulty  using the radiator I was supplied. It was an aftermarket aluminum one and was too thick to fit.  So off to the supplier to find a stock sized Mini one.. This picture shows how far over the rad would have to be to clear the side on the inner fender well.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:50:46
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New radiator fitted and ready to drop the body over..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:51:38
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Down she goes....

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 15th, 2022, 02:53:41
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And shes in.. now to finish up with the rest of the bolts, add the shifter rods, exhaust manifolds, carb distributor and hook up all the engine wiring..   custom gas tank out being Tig welded up so have to get that back before I can think about firing it up.

Mike in Victoria BC - building 8042

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mike brown
Posted on: June 17th, 2022, 17:32:40 Quote Report to Moderator
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Great progress. It's going to be a sweet car once done.
Mike
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Mike_Smith
Posted on: June 26th, 2022, 02:39:06 Quote Report to Moderator
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Quoted from mike brown, posted June 17th, 2022, 17:32:40 at here
Great progress. It's going to be a sweet car once done.
Mike




Thanks for the kind comments!  

Mike in Victoria BC - building 8042
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Mike_Smith
Posted on: June 26th, 2022, 02:51:09
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Picked up the custom fuel tank I was having welded up today.. will allow a lot more distance between fill ups.  Now to fit it to the car and align the filler tubes.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 26th, 2022, 02:57:54
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With the engine and front sub frame in place I was also able to cut out the hole for the shift lever and the mounting bracket holes. Now installed on the car.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 28th, 2022, 04:29:01
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Fuel tank mounted in the car..

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 28th, 2022, 04:30:01
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Filler tube with gas rated hose and stainless T clamps

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 28th, 2022, 04:30:38
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Locking gas cap to finish it all up.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 28th, 2022, 04:31:44
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Seat belts fitted to car.. will have to come out to fit the carpets.. but I now lknow they will work.

Mike in Victoria BC - building 8042

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Posted on: June 28th, 2022, 04:32:12
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Rear belt bar.

Mike in Victoria BC - building 8042

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Mike_Smith
Posted on: June 28th, 2022, 04:33:49
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Engine pretty much plumbed and cables sorted. Just needs heater hoses and the last bit of wiring for the starter solenoid and ignition system.

Mike in Victoria BC - building 8042

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