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1981 Mini City 1000

This section is for Mini projects and restorations and also the place to show off your pride and joy.

Moderators: irishminis, spud1979, The Marcos Graveyard, Moderators

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The Marcos Graveyard
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Posts: 4697
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Sat Jun 13, 2020 7:24 pm

How much advance would there be just by moving one tooth on the cam gear?


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A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
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Re: 1981 Mini City 1000

Post by ctwomey » Sat Jun 13, 2020 8:09 pm

The Marcos Graveyard wrote:
Sat Jun 13, 2020 7:24 pm
How much advance would there be just by moving one tooth on the cam gear?
There are 40 teeth on the camshaft gear, so that is 9 degrees per tooth. Woodruff keys are available from 0 - 9 degrees.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Mon Jun 22, 2020 10:58 am

Gearbox finally finished and looking sweet too.

Once the engine is finished I am going to try and run it outside the car, that way I can do some checks and tuning plus check for oil leaks from the gearbox or engine.

Has anyone run an engine outside of the car before?

I still a few items to address first on the engine (distributor, carburetor, oil filter housing, inlet and exhaust manifolds and flywheel and clutch) plus I have a bunch of parts that I need to shot blast and paint.
IMG_2498.jpeg
IMG_2500.jpeg
Installed some old CV joints to enable the running outside of the car.
IMG_2503.jpeg
IMG_2504.jpeg
IMG_2507.jpeg

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4697
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Mon Jun 22, 2020 1:00 pm

Ronan had a stand for running engines on back in the day, frame to hold the engine and a panel with a few gauges to check oil pressure, water temp, rev counter that sort of thing
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A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Thu Jul 09, 2020 10:40 pm

Finally got the 5 degrees offset woodruff key. Re-ran the timing with it installed and discovered I put it in the wrong way round. Anyway, changed it around again and now have the timing at 107 degrees as per the camshaft spec.
IMG_2607.jpeg
Oil pump and core plug installed at the end of the block. I use Loctite 638 bearing retainer liquid on the water and oil core plug edges.
IMG_2609.jpeg
Plenty to do over the coming weeks as I have almost all parts to completely assemble the engine and the gearbox.
IMG_2612.jpeg
I have been busy shot blasting, priming and spraying a lot of the old parts such as the timing chain cover, tappet covers, rocker cover, and radiator cowling plus a host of smaller parts. I used satin black as I want to keep it as close to the original factory look as possible. Always felt that gloss was too shiny. I didn't powder coat them or use a 2K paint for a number of reasons. In lockdown too much hassle to get all the powder coating done and the 2k paint isocyanates are too dangerous to use at home. I used 2 x coats of primer and 3 x coats of satin 1k chassis black.

I have also restored the old inertia starter motor and it looks really great. I also have deep cleaned the SU HS4. Will post pictures of before and after when they are finished.

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4697
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Fri Jul 10, 2020 12:09 am

Love this, great work.
Image

A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Thu Jul 16, 2020 2:30 pm

Finally got the gearbox and engine bolted together. The engine stand is a dream to work with.
IMG_2620.jpeg
IMG_2621.jpeg
Also bolted on the flywheel housing. I noticed the front mounting bracket is missing so I will have to source one and also slightly longer studs to support it's 5mm thickness.
IMG_1898.jpeg
IMG_7708.jpeg
Did some research and it appears that the Victor Reinz composite head gasket is the most reliable on the small bore engines.
IMG_2591.jpeg
Head all torqued up too. I have 3 x torque wrenches to work on engines. One for the 5-12NM, 12-60NM and this one for 40-210NM. Takes all the guessing out of assembly.
IMG_0554.jpeg
I was originally going to buy a lightweight flywheel but the more I read the more I realised it's a waste of money on this engine. So the old pre-verto is a bit rough so I am cleaning it up and then going to get the clutch surfaces remachined to take any grooves out of them and return them back to factory smooth.

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4697
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Fri Jul 17, 2020 12:36 pm

Is your oil pressure gauge union going to clear the feed pipe to the oil filter at that angle ?
Image

A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Fri Jul 17, 2020 1:03 pm

The Marcos Graveyard wrote:
Fri Jul 17, 2020 12:36 pm
Is your oil pressure gauge union going to clear the feed pipe to the oil filter at that angle ?
Never thought of that. I am planning on using a billet oil filter housing (to get rid of the dreaded bypass valve) and a braided stainless steel line to the filter housing so that might clear it. Otherwise I will have to adjust the oil pressure gauge union.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Wed Jul 29, 2020 9:13 pm

Getting around to restoring some of the ancillaries for the engine.

Starter motor heavily rusted on the outside
IMG_2542.jpg
But after a strip down, clean, shot blasting and a few coats of satin black paint it has come out really well.
IMG_0422.jpg

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Fri Jul 31, 2020 2:45 pm

Carb has cleaned up pretty well.

Dismantled, cleaned, soda blasted and finally a low pressure glass bead blasting to get the shine back. Butterfly spindle needs replacing as it is worn which I will need to order but I have the standard service kit for the rest of the wearables.
B5627C03-1CA7-459E-B3BE-812E3595E295.jpeg

User avatar
The Marcos Graveyard
IMOC Paid Member
Posts: 4697
Joined: Fri Feb 04, 2005 10:05 am
Whats your location?: Longford
Region: Eastern
What Minis have you?: 1971 Mini Marcos.
1984 Mini Sprite
Modifications: 1380cc
Weber45
S/C CR gearbox and drop gears
Location: Longford
Contact:

Re: 1981 Mini City 1000

Post by The Marcos Graveyard » Thu Aug 06, 2020 9:38 pm

Great work again.

Maith an fear.
Image

A fully carbon fiber Mini Marcos shell weighs just 7.25kg.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Wed Aug 19, 2020 4:44 pm

Pre verto flywheel has cleaned up well and both the clutch face and the internal tapper face are in excellent condition with no signs of fretting.
IMG_2661.jpeg
Unfortunately the clutch pressure plate is a mess and I suspect it was switched out at some point with the original because there is no way these both came off the same car. The machine shop recommended replacing it instead of trying to machine it, so will replace it with an EN8 steel one instead. It will save 1Kg in the overall mass of the flywheel assembly, nothing to drastic.
IMG_0919.jpeg
Hope everyone is keeping safe.

ctwomey
NON Member
Posts: 29
Joined: Thu Jan 03, 2019 9:44 am
Whats your location?: Ballybrittas, Co. Laois
Region: Eastern
What Minis have you?: I owned a 1977 Mini 850 when I was in my late teens. I owned a 1986 Mini Chelsea that I imported from the UK. Also owned a MG Metro that was bored out to 1293. Restoring a 1981 Dublin Mini City.
Contact:

Re: 1981 Mini City 1000

Post by ctwomey » Sat Sep 12, 2020 8:24 pm

Finally new clutch back plate arrived. It's 1.22 Kg lighter than the stock one. It will be great to lose a little weight off the flywheel clutch setup without going for a light weight steel flywheel.
IMG_3457.jpeg
Took the engine and gearbox off the stand. Installed a new oil filter housing, braided hose and inserted the last two core plugs that I couldn't access while on the stand.

I also attached the oil pressure gauge and have been able to get a small bit of pressure just turning the engine over with a socket on the pully bolt.

Only things left to order are new dizzy, exhaust and inlet manifolds. Should be ready to attempt a start then.
IMG_3459.jpeg

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