I already know that from the other peoples builds I've seen that the front section of the subframe has to be removed. In addition to this, the Starlet CV cups are too big to fit through the standard subframe portals. As a consequence of that, the lower control arm mount location will need to half cut off and and rebuilt using some plate steel.
First step was to figure out how much of the lower control arm area can be removed. I put the arm in place and measured the width of the arm including bushes.
A line was scribed which at 42mm which set the line for cutting...
and a few cuts later, the front of the subframe was off. I also bolted the front subframe section (which was made months ago) onto the jig.
The next step was to do a test fit with the engine. I used an engine leveller with the crane to ensure that it was level...
and lower the engine into the jig to match the height of the original Mini drive shafts (Well - close enough for now). It's times like this I regret refurbishing and painting the engine before everything else as I can had to be quite careful not to scratch any of the paint.
I already knew the gearbox would foul against the rear of the subframe.
I marked out a few lines and cut that section out
The hole was not big enough to let the gearbox move towards to the rear of the subframe, so I cut some more out and the gearbox could now clear the subframe with at least 10mm clearance all round.
This has weakened this area of the subframe quite significantly so once the custom subframe is complete, I will add and weld some plate to this area (and other areas) of the subframe to strengthen it for the Starlet engine. Consideration MUST be made that the subframe has to hold and handle 150hp which is 2-3 times the standard or modified Mini engine would be.
Another problem is that the gear shifter arm fouls against the subframe tower so for now, the triangle piece visible in this pic was cut out and I will have to deal with this later - Maybe cut and reweld the arm?? but retaining the correct movement range.
Next step is to start designing where the tube will run and join the subframe towers to the front.
First step was to figure out how much of the lower control arm area can be removed. I put the arm in place and measured the width of the arm including bushes.
A line was scribed which at 42mm which set the line for cutting...
and a few cuts later, the front of the subframe was off. I also bolted the front subframe section (which was made months ago) onto the jig.
The next step was to do a test fit with the engine. I used an engine leveller with the crane to ensure that it was level...
and lower the engine into the jig to match the height of the original Mini drive shafts (Well - close enough for now). It's times like this I regret refurbishing and painting the engine before everything else as I can had to be quite careful not to scratch any of the paint.
I already knew the gearbox would foul against the rear of the subframe.
I marked out a few lines and cut that section out
The hole was not big enough to let the gearbox move towards to the rear of the subframe, so I cut some more out and the gearbox could now clear the subframe with at least 10mm clearance all round.
This has weakened this area of the subframe quite significantly so once the custom subframe is complete, I will add and weld some plate to this area (and other areas) of the subframe to strengthen it for the Starlet engine. Consideration MUST be made that the subframe has to hold and handle 150hp which is 2-3 times the standard or modified Mini engine would be.
Another problem is that the gear shifter arm fouls against the subframe tower so for now, the triangle piece visible in this pic was cut out and I will have to deal with this later - Maybe cut and reweld the arm?? but retaining the correct movement range.
Next step is to start designing where the tube will run and join the subframe towers to the front.
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