Page viewing: Fitting suspension
Steering
 
The steering rack needs to be bolted to the subframe before fitting the subframe.

The mini steering column is shortened slightly and the metro U/J is welded to the end.

Std steering column
std steering column
Column clamped in place to see were it needs to be cut,
new stronger top bracket has been fabricated.
cutting outer column
Column being slotted
std steering column
Bottom of the outer column being cut
cutting outer column
U/J welded to the steering shaft
std steering column
Sleeve welded over joint to add strength
cutting outer column
Here it is in primer
std steering column
Trial fit of column
cutting outer column
Trial fit of column,
brake pedal just hits the U/J when depressed.
std steering column
The new top bracket
cutting outer column

Brakes
 
I am using Rover MGF vented brakes and calipers with EBC green stuff brake pads, they are the same as Rover Metro GTI MPI and Montego brakes.

I will not be using a servo and so using a master cylinder with the correct bore size is essential to get brakes that work efficiently.

Some members of the 16 Valve Mini forum have had success with using a Girling 0.625 bore master cylinder, I have ordered one from Merlin Motorsport.
Total cost £95, this includes all associated parts - resevoir, resevoir bracket, resevoir hose + fittings, adjustable clevis pin and P£P

I will also be using the smallest bore rear wheel cylinders (part No GWC 1126, bore 12.7mm) in an attempt to balance the braking without the need of a brake front/rear regulator.

For info rear wheel cylinder bore sizes:
GWC1126 - 12.7mm
GWC1131 - 14.29mm
GWC1101 - 15.88mm
GWC1129 - 17.46mm
GWC1102 - 19.00mm

Modified brake pedal
Modified brake pedal
Modified brake pedal
cutting outer column
Modified brake pedal
cutting outer column
Modified brake pedal
cutting outer column
Pedal box and steering column fitted
pedal box and steering column fitted
Pedal box and steering column fitted
cutting outer column
Pedal box and steering column fitted
pedal box and steering column fitted
Mini master cylinder and new master cylinder comparison
Master cylinder
Picture shows which brake union is needed for front brake pipe to brake hose connection
pedal box and steering column fitted
Picture shows the correct brake pipe flare needed for front brake pipe to brake hose connection
Master cylinder
Brake hose bracket hole needs enlarging and shaped so that hose fits through it
pedal box and steering column fitted
Brake pipe flaring tool kindly loan to me by Steve, highly recommended if you need a flaring tool
Master cylinder
Master cylinder fitted
pedal box and steering column fitted
Difference between old mini master cylinder and new
pedal box and steering column fitted

Suspension
 
The Watsons kit uses coil springs in place of the original metro hydrolastic units.

Suspension being fitted, spring cover removed
cutting outer column
Fully fitted front suspension
cutting outer column
Fully fitted front suspension
cutting outer column
Here you can see the wide track of the metro frame and why the wheels will stick out a lot from the bodywork
cutting outer column
Trial fit of the wheels
cutting outer column
Trial fit of the wheels
cutting outer column

Driveshafts
 
The metro outer CV/driveshaft utilises a circlip and spring clip, the new Watson driveshafts only uses the spring clip.

The Honda inner CV/driveshaft utilises two circlips which are also used on the new driveshafts.

CV'c fitted to new driveshafts
Tower bolts