Keeping your Mini alive is all about smart upgrades and repairs. In this post, we dive into Mini Sport Ltd's process for replacing a rusty door and explore weight-saving modifications for a more performance-focused Mini.
Mini Doors - Replace or Upgrade: Bogus 2 Build
From Rust to Revival: Replacing a Door Shell
Our donor Mini's passenger door was beyond saving, riddled with rust. Thankfully, the driver's side door frame, while showing surface rust, had potential. Here's how Mini Sport Ltd brought it back to life
1. Stripping Down to Bare Metal:
The process began with removing all paint and rust using a combination of stripping and shotblasting. Afterward, the frame received an etch primer to prepare for the next step.
2. Seaming Up for a New Skin:
After drying, the seams were coated with a bonding agent and smoothed to create a seamless base for the new door skin. Replacing a door skin requires precision, as achieving the correct shape is crucial. Originally, Minis were built with doors stretched to fit the frame using hydraulic rams. Here, the opposite approach is taken.
3. Weight Reduction with Lexan Windows:
Since we're using lightweight Lexan windows, the heavy standard window winder mechanism and glass could be removed. This saves significant weight, but Lexan is not as strong as glass. To maintain structural integrity, the inner panel (except for the beveled edge) is kept. Removing this small edge makes a big difference in the door's overall strength. Carbon fiber door panels and different door releases will be added later.
Painting and Additional Touches
Lightweight Champions: Doors & Boot lid
The lightweight steel doors and carbon fiber bootlid received a two-pack paint job and were left to cure in a warm booth. While carbon fiber offers flexibility, the paint's elasticity allows for proper adhesion. Some paints require additional plasticisers for flexible panels.
Matching the Shell: Consistent Paint Across Components
The bonnet, a Mini Sport fiberglass item, received pre-drilled slots for quick-release catches during a trial fit before painting. Notably, the same paint batch used on the car's shell was applied to the bonnet, bootlid, and doors, ensuring a perfect color match. This consistency was achieved by painting everything in a controlled environment within the booth.
Drilling and Paint Touch-Ups:
Unfortunately, adding components like corner gussets often requires drilling new holes in the shell. Here, Mini Sport Ltd emphasizes the importance of touch-up paint to preserve the integrity of the overall painted surface.
Wheel Arch Extensions: Selecting the Right Fit
The final touch? Wheel arch extensions! These are chosen based on your chosen wheels and tires. Mini Sport Ltd opted for Mini Sport Monte Carlo arches, which mount from the inner lip, avoiding drilling into the car's body. This allows for easy removal if needed. Remember, ensure your car's ride height prevents tyre rub against the arches.
By following these steps and considering our expert advice, you can breathe new life into your Mini's doors and achieve a weight-efficient upgrade!
Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here
Don't miss out on the rest of the Bogus 2 Series!
This blog series is your one-stop shop for following Bogus 2's incredible journey from a bare shell to a road-worthy classic. Check out the rest of the series for tips and advice for every stage of your Mini restoration!
Don't settle for an ordinary Mini. At Mini Sport Ltd., our passion for motorsport fuels our expertise in building winning machines. We offer the knowledge, parts, and guidance you need to optimise your Mini for performance.
Contact us today and let's turn your vision of a motorsport champion into reality..