Door skins

I’d hoped to simply patch the rusty bits on the Mini’s door, but welding a large, mostly-flat panel without distortion is difficult. It’s far easier to just fit new door skins.

I used an angle grinder to grind through the folded-over edge all the way around the door panel.

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Unsurprisingly, the door frame needed some rust repair.

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The new door skins were tidied up around the edges…

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The edges are carefully folded over…

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It’s important to test fit the door, because the fit of the outer skin can change the door’s shape. Once the door was twisted into the right shape, a couple of welds on the door skin locked it into place.

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Exhaust system

While I’m working on the body panels, Brian’s fitting the exhaust system. The RC40 is fairly standard for a Mini, but in the interests of longevity we’ll have it ceramic coated by the guys at HPC. The ceramic coating cost about $250, but the exhaust on a Mini is a complete arse to replace so I want it to last as long as possible.

Before:
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And after ceramic coating:
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Bonnet fit

I’m always disappointed with the panel fit on Minis. Yes, I know they were built down to a price, are practically disposable, and are 50 years old, but bugger it, I’m going to take some time and improve the panel fit. Make the gaps parallel, at least.

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