Richard's Mini Pickup

The Restoration of my 1975 Morris Mini Pickup

Month 27

Due to strikes and roadblocks, my time in Tarija was limited to 3 days, but I got started on the engine to figure out what I need to order.

I took off the trumpets I had polished for the rear suspension and installed adjusta-rides.

I ran a compression check and found that the new engine only had 50 to 70 psi compression instead of the 130-190 psi recommended, so I set out to clean it and take it apart to find what is wrong. An obvious (unrelated) problem is the thermostat is missing its seal and the water pump, hoses, and housing were full of rust and particles, apparently from not using coolant and then using a strong cleaner (which wasn't completely rinsed).

While I was at it I cleaned and painted the exhaust manifold and polished up the intake manifold and part of injection body, as well as the oil filter adapter and thermostat housing.

When I come back I'll rig up a soda blaster and work on the rest of the injection body.

The cylinders checked out close to spec, but the bearings are at the end of their spec. I ordered bearings and rings, plus the water pump, thermostat and other things from Mini Sport in the UK to install next month, as well as rear bumpers from DSN Classics in the UK.

The body shop cut up the pickup and aligned the parts to weld. You can see how it is going toghether with the front and doors from the 84. They were waiting for the windshield gasket to weld to the correct dimensions (lost the old one). In this series you can see how he is cutting and welding to widen the door opening and correct the roof corners for the wider door with roll up windows. He also had to modify the door sills and frames for the different with and sealing surfaces. I recommend that when piecing the windshield posts together, you should make sure the inside of the driver’s pillar is smooth as you will need to pass up to 8 wires through it.

The engine parts arrived from Mini Sport, so when I get to Tarija I'll assemble the engine. I also got my heat shield back from the chrome shop. My son in San Diego (California) sent me the tail light lenses he was able to find at a swap meet (I later learned that these lenses are available if you shop for Rover P4 lenses).

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Tearing down the new engine for rebuild and work on fitting the two pieces together

View of left side with new parts aligned

View of right side with new parts aligned

Interior showing alignment of floor and beam

Adjusta-rides installed on rear sub frame

Cleaning engine after soaking with diesel fluid

Pulling torque converter to get at the lower end

Water pump filled with rust

Thermostat missing seal

Rusty exhaust manifold

Intake and exhaust manifolds cleaned, polished and painted

Thermostat housing on engine

Thermostat housing after cleaning

Oil filter housing cleaned

Injector body half cleaned

Cylinder head cleaned

Timing Chain and tensioner

Underside of engine after removing transmission

Worn main bearing

Plastigage shows bearings at outer limit of spec

Windshield pillars welded together

Hydraulic jack holding parts to weld

Welding interior of rocker panels together

Rocker cut out to form new corner for door

Sliding door frame parts back to fit the larger door

Forming new corner for larger window

Corrected Roof Line

Interior of cabin with new door sizing

Rocker panel cut out to weld and replace

Squaring body and welding

New tail light lenses

Bearings, rings, water pump, thermostat, valve cover, gaskets, dual timing chain kit, etc.

Heat shield chromed

The following video shows how the upper portion of the cab was sliced and moved over 30 mm to match the width of the new doors with roll up windows. The fenders were also cut this way, with the door frame pushed back 19 mm to widen the opening.

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