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Default 15th October 2017, 09:18 AM

Great job.
Just out of interest, why did you paint the JCW calipers Black, rather than Red?
  
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2002 Dark Silver MCS - One for life
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Default 2002 Dark Silver MCS - One for life - 15th October 2017, 03:41 PM

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Originally Posted by Oakleyguy View Post
Great job.

Just out of interest, why did you paint the JCW calipers Black, rather than Red?


They are R56 calipers, branded by myself as JCW as they are the same brakes. Brakes get dirty, red shows the dirt, nothing more simpler than that.


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2002 Dark Silver MCS - One for life
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Default 2002 Dark Silver MCS - One for life - 11th November 2017, 09:40 AM

Started on the driver's side restoration, impatience and the need to do something to keep the mind clear. This is what I am faced with.








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Default 2002 Dark Silver MCS - One for life - 11th November 2017, 09:49 AM

Having the correct tools and practice had made the dis-assembly of this side easier, but of course not without it's issues one still unresolved, awaiting a grinding cutting disc delivery.

I again had to remove the hub assembly as a complete unit. Do we all just love rust........







A pile of rusty parts to sort out or replace, parts and paint ordering has commenced again.



The outer ball joint could not be removed, rounded nut and lots of rust, the pickle fork could not remove it, eventually after cutting the nut off a very large hammer hit many times released it, hit away from you and in the direction of nothing of value, it took down a number of my Lin bins on the walls.

Currently soaking the drive shaft and brake line bracket in deox c gel.







This is currently being very stubborn, access is limited as I am not removing the drive shaft. The bolt rounded and even my Irwin bolt extractors are also failing, next step is to cut the ball joint bracket off and see how that goes.




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Default 2002 Dark Silver MCS - One for life - 11th November 2017, 09:52 AM

I eventually replaced the bonnet release cable, I now have a bonnet that opens on both sides without having to go in under the wheel arch.



I also had a go at restoring the original wheel bearing.





Now sat in the parts box covered in oil.


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Default 2002 Dark Silver MCS - One for life - 12th November 2017, 12:23 AM

I've just read this entire thread. Wow. What amazing hard work and what a lovely mini you have.


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Default 2002 Dark Silver MCS - One for life - 16th December 2017, 12:04 PM

Drivers side Components going through extensive rust removal











Wheel bearing hub before during and after









Wishbone before during and after







Box of new components waiting to be assembled and installed




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Default 2002 Dark Silver MCS - One for life - 18th January 2018, 06:48 PM

The difficultly in removing the inner ball joint continued and eventually was removed with 1500mm breaker bar (old curtain pole), not before I slipped with a pry bar and split the inner CV Rubber boot. So I had to remove the driveshaft which I was not planning to do which created much greater access to the seized bolt.

42 later from BMW I had a new rubber boot and clips. Whilst out I thought I would refurbish the drive shaft.

Initial plan was to improve insitu, deox C gel cleaned it up.





Once off the car I could strip it down, circlip removed, tripod bearing gently tapped off, remaining rubber boot removed, 16 year old grease cleaned away, lots of emery cloth on the shaft followed by deox c gel to enable painting and re-assembly with new parts.








All parts are now refurbished and ready to be reinstalled, I just need to do some scrubbing of the wheel arch and a little bit of surface rust removal before painting and then I get get it all back together and off the axle stands.


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Default 2002 Dark Silver MCS - One for life - 18th February 2018, 07:07 AM

All the surface rust which was minimal was ground back to bare metal, treated with deox-c, zinc primed, seam sealed, stone chipped and then a top coat, all for preservation purposes. It was the healthiest corner of the car with minimal surface rust mainly on the spot welds. I then applied where needed some clear cavity wax.









With a new inner ball joint installed


The tie rod end was rather difficult to remove and took about 5 minutes of constant heat from a butane burner (16 years of activity).

Eventually the driver's side is now all re-assembled

Ending up replacing the following with new

Inner ball joint
Outer ball joint
Track rod end
Wheel bearing
Inner cv rubber boot
Brake disc plate
ABS sensor
Every bolt

During the re-assembly process





All back together



  
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Default 18th February 2018, 06:22 PM

Good work, this will all look brand new when you complete the work.


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