Before fitting the main dash panel, the Toyota Starlet instrument cluster had to be mounted. The cluster was fixed in place via two slots made in the lower dash panel and a custom bracket welded at the top.
The standard plastic cover on the factory cluster was too large to fit within the Mini dash
I trimmed the black surround piece and sanded it down on my linisher to form a (relatively) flat surface instead of the curve in the above photo.
After creating a CAD (DXF) file for a local plastics company, I had them laser cut a piece of 2mm acrylic (perspex) laser cut to use as the replacement protective cover. I glued on some small acrylic tabs to this piece so that the cover could then screw onto to the the main cluster. The grommet in the acrylic piece is for the odometer reset pin - which I had to shorten to fit the new cover.
To ensure a good dust seal, I will put a small strip of foam around the edge of the black surround piece. The protective coating will only be peeled off at the point of final install.
With the cluster bolted into place, I marked and cut a small hole in the firewall for the speedo cable. The factory Toyota Starlet speedo cable was too long to fit in the Mini so to measure the required length, I made a mockup using some brake line and a short length steel pipe, where the pipe slipped over the connector on the back of the instrument cluster.
I had a local company Flexible Drive here in Perth make a custom length cable to match. The new cable ended up being far more flexible than the original cable, which was very stiff.
Thanks to the oval-shaped indent in the firewall, the hole for the speedo cable could not be flat and I could not use a simple grommet for passing the speedo cable through, so using some 2" tube and flat sheet steel I made an adapter piece for the firewall.
The hole in the firewall was enlarged and with the tube trimmed to shape, it was welded in place. I will finish off the welds when the engine is next out of the engine bay.
I punched a small hole in a standard grommet and stretched it over the speedo cable end, and this sealed the firewall hole.
Given that the Mini tyres are ~20% smaller circumference than tyres fitted to the Toyota Starlet, the speedo and odometer will likely not be accurate so I will have to compare the speedo dial vs actual speed and consider options to resolve any discrepancies eg Mechanical speedo ratio adapter, but this will happen only once the Mini is driveable.
The standard plastic cover on the factory cluster was too large to fit within the Mini dash
I trimmed the black surround piece and sanded it down on my linisher to form a (relatively) flat surface instead of the curve in the above photo.
After creating a CAD (DXF) file for a local plastics company, I had them laser cut a piece of 2mm acrylic (perspex) laser cut to use as the replacement protective cover. I glued on some small acrylic tabs to this piece so that the cover could then screw onto to the the main cluster. The grommet in the acrylic piece is for the odometer reset pin - which I had to shorten to fit the new cover.
To ensure a good dust seal, I will put a small strip of foam around the edge of the black surround piece. The protective coating will only be peeled off at the point of final install.
With the cluster bolted into place, I marked and cut a small hole in the firewall for the speedo cable. The factory Toyota Starlet speedo cable was too long to fit in the Mini so to measure the required length, I made a mockup using some brake line and a short length steel pipe, where the pipe slipped over the connector on the back of the instrument cluster.
I had a local company Flexible Drive here in Perth make a custom length cable to match. The new cable ended up being far more flexible than the original cable, which was very stiff.
Thanks to the oval-shaped indent in the firewall, the hole for the speedo cable could not be flat and I could not use a simple grommet for passing the speedo cable through, so using some 2" tube and flat sheet steel I made an adapter piece for the firewall.
The hole in the firewall was enlarged and with the tube trimmed to shape, it was welded in place. I will finish off the welds when the engine is next out of the engine bay.
I punched a small hole in a standard grommet and stretched it over the speedo cable end, and this sealed the firewall hole.
Given that the Mini tyres are ~20% smaller circumference than tyres fitted to the Toyota Starlet, the speedo and odometer will likely not be accurate so I will have to compare the speedo dial vs actual speed and consider options to resolve any discrepancies eg Mechanical speedo ratio adapter, but this will happen only once the Mini is driveable.
Very nice work arounds Mate!
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