shows the underside of a classic Mini coated with stonechip protection to prevent rust and damage from road debris.

Welcome back to the Bogus 2 build series, brought to you by Mini Sport Ltd.! Today, we're revisiting a crucial aspect of the restoration process – body repair.

While our previous blog posts delved into the details of the repairs, this one focuses on practical tips you can apply to your own classic Mini. We'll be drawing on insights gleaned from Bogus 2 and the expertise of our Mini restoration specialists.

Stonechip Protection: Don't Forget the Underside!

While Bogus 2 didn't receive stonechip protection for the entire underside, it's a valuable addition for many classic Minis. This protective coating shields vulnerable areas from the harsh elements they encounter on the road. At Mini Sport, we typically recommend stonechip paint for the sills, but a full underbody coating can be a great option for added peace of mind, especially for cars that see frequent use! Ready to shield your Mini from road debris? Contact us today to discuss stonechip protection options!

Sealing the Seams: Keeping Rust at Bay

Seams are a potential weak spot for rust development. As you can see with the Bogus 2 front wing and front panel, even seemingly small gaps can invite trouble. That's why proper seam sealing is essential. We recommend treating all seams, including the headlight ring, to create a barrier against moisture and corrosion.

Close-up view of a seam on a classic Mini's front wing, highlighting the area that requires sealing to prevent rust.

Seam Sealer Application

Applying seam sealer requires a delicate touch. The goal is to inject a bead deep into the seam using a continuous, steady motion (ideally after the panels have been dried thoroughly). Use your finger to push the sealant in, leaving a visible seam line. Don't overfill, as this can lead to paint cracking later.

After applying the sealant, remove excess residue with thinners (remember, this example uses bare metal, but ideally, sealing happens after priming). The key here is timing. The sealant should be tacky when the final paint layers are applied, allowing for proper adhesion. Completely dry sealant will lead to paint cracking.

A technician applying seam sealer to the joined panels of a classic Mini during the body repair process.
A technician using their finger to push seam sealant deeper into the joined panels of a classic Mini for a watertight seal.
Technician cleaning excess seam sealant residue from a classic Mini panel after application.

Joddling Panel Edges: An Alternative Joining Method

Joddling is an option for joining larger sheet panels. This technique creates a step in one edge, allowing the other panel to fit snugly in the seam. Joddler tools can also punch holes for plug welding, but keep in mind that these areas may require additional sealing and welding for a watertight finish. Mini Sport often favors other methods due to these additional steps.

A tool called a "joddler" being used to create a step in the edge of a classic Mini panel for a secure join during body repair.

Clamping Solutions for a Flawless Finish

Clamping the joined sheets is crucial to avoid distortion. Our example showcases handy Micro clamps, perfect for creating a flat and secure seam.

Remember, these are just a few key body repair tips, we always recommend contacting a reputable body repair expert! For a comprehensive restoration experience and access to top-quality parts, contact the experts at Mini Sport Ltd. We're here to help your classic Mini reach its full potential!

Close-up view of a joddling tool punching holes in a classic Mini panel for potential plug welding during body repair.
Mini body repair in progress, showing two clamped classic Mini panels to ensure a flat and secure seam.

Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here

Front Cover of the Keeping Your Mini Alive Magazine

Need help? No matter the condition of your Mini's body, our team of passionate restoration specialists is here to breathe new life into it! From battling pesky rust to perfecting panel gaps, our extensive knowledge and vast selection of Body Panels ensure we have the tools and expertise to tackle any body repair challenge.

Contact us today and let's discuss how we can transform your Mini into a legend

Stay Connected with Mini Sport:

Follow us on social media for the latest news, restoration tips, project updates, and to see more classic Minis brought back to life!

Welcome back to the Bogus 2 build series, brought to you by Mini Sport Ltd.! Today, we're revisiting a crucial aspect of the restoration process – body repair. While our previous blog posts delved into the details of the repairs, this one focuses on practical tips you can apply to your own classic Mini. We'll [...]
Stripped Mini shell mounted on a rotisserie for rust repair.

With the shell stripped bare in Part 2, we are now ready to tackle the inevitable: rust and hidden repairs. Our team of experts is equipped with the knowledge and tools to bring your Mini back to its former glory.

The Rotisserie:

With the shell stripped clean, it gets secured on a rotating frame, also known as a spit or rotisserie. This ingenious tool is a game-changer for classic Mini repairs:

  • Maintaining Shape: The rotisserie helps the shell retain its original shape during repairs.
  • Easy Access: Effortlessly reach every part of the shell for repairs from a comfortable standing position.
  • Painting Efficiency: The rotisserie can even be moved into the spray booth, streamlining the painting process and ensuring optimal coverage.

This setup significantly reduces painting time while guaranteeing a flawless finish. However, depending on the frame used, later Mini shells might require a small cutout in the rear firewall, similar to the Mk1 or Mk2 shells.

Applying paint to a shell secured on a rotating stand after repairs.

Unearthing the Past: Common Mini Issue

The true extent of corrosion and previous repairs often becomes evident only after removing panels. Our donor Mini's scuttle panel, for instance, was in dire need of replacement due to severe creasing and patchwork repairs. This process also revealed a corroded shut-off plate at the top of the arch and a rust hole behind the front top damper mount.

Damaged scuttle panel of a Mini removed for repair, showing extensive body filler use.

Inner Wing issues & solutions

Heavily patched inner wings are a common issue with classic Minis. In such cases, replacing the entire panel can be more efficient than attempting extensive repairs. We used a specialized spot weld removal drill bit to save time and minimize distortion while removing the old welds.

For the new inner wings, spot welding was the preferred method whenever possible. Plug welds were used in areas where spot welding wasn't feasible. It's important to note that some pre-assembled inner wings with A-panels can cause fitting issues. New body panels from reputable suppliers like Heritage typically come with a black finish, which should not be mistaken for a reliable undercoat.

Patched inner wing of a Mini shell, highlighting a common repair area
Mini shell with a new inner wing panel welded on, showcasing the different repair techniques

Preparing for the New Floor

With the floor section cut out, the connecting edge of the bulkhead needs thorough cleaning and rust treatment before the new floor is welded in place. This critical step ensures a strong and rust-free connection between the new and existing panels. Furthermore, the shell must remain on the rotisserie during this process to prevent any warping.

Rusted floor section cut out of a Mini shell, exposing corrosion damage.

Door braces play a vital role in maintaining the shell's shape while the new floor is clamped in position. A crucial aspect is ensuring the rear subframe fits perfectly into the designated boot floor holes. The only modification needed on the British Motor Heritage floorpan in our case was elongating the holes for accessing the captive nuts in the heelboard, without compromising the integrity of the trunnion bolts.

Door braces used to maintain the shape of a Mini shell during repairs.

Spot On Welding

Mini Sport Ltd. prioritises replicating the original Longbridge factory methods by utilising spot welding for a strong and lasting bond between panels. The number of welds applied matches or even surpasses the original amount to comply with Thatcham vehicle repair regulations. For areas where spot welding isn't suitable, plug welds are implemented using a MIG welder.

Here's a breakdown of the plug welding process:

  1. Precise holes are drilled through the top panel.
  2. Joining surfaces are meticulously cleaned and coated with a zinc-rich weld-through primer.
  3. The panels are fused together using a MIG welder.
  4. The welded seams are then ground and smoothed out for a clean finish.
Plug welding process with a MIG welder being used for Mini bodywork repair.
Technician using a hammer to check alignment of Mini body panels during repair.

Precise Panel Replacement

A significant portion of the rear quarter panel required attention. Ensuring a perfect match between the new and existing panels with no gaps is paramount. To achieve this, the new panel is meticulously trimmed using a fine air saw to align flawlessly with the original contours. The panel is then tack-welded, ground, and allowed to cool completely before continuing.

Patience is key in this process!

To prevent distortion, avoid making continuous spot welds initially. Instead, use a staggered approach with short welds, allowing them to cool completely before adding new welds in the middle and then halving the gap again. Once the entire joint is tacked, a low-power seam weld finalises the bond.

Rear quarter panel of a Mini undergoing repair work.

Using cool damp cloths to cool down the metal is counterproductive as it introduces moisture, which can negatively impact the weld strength. Heat buildup is the primary concern when joining two panels. Welding everything in one go can lead to panel distortion. Joddling (also known as jogging) the panel is another possible method.

Metal Thickness

The appropriate weld amperage depends on the thickness of the metal being joined. Common Mini panels are typically made from 18- or 16-gauge steel, which translates to 1.27mm and 1.59mm thick respectively. After welding, the panel can be ground flat to create a smooth surface, as seen in the image.

Repaired Mini rear panel ground flat to create a smooth surface.

Weld Penetration and Sound Deadening Removal

The quality of your welds can be checked by examining their penetration on the inside of the joint. A proper weld should completely fuse the two panels together. This area also reveals the original sound deadening material.

Removing sound deadening can be a challenge. Cold material might chip off easily, while more stubborn areas may require a heat gun to loosen its grip. It's crucial to remove all sound deadening before welding to eliminate fire hazards. While time-consuming, this process also helps reduce weight, a benefit for this particular car.

Weld penetration inspection on the inside of a repaired Mini panel.

Scuttle Panel Replacement 

Spot welding secures most of the scuttle panel along the window opening. The A-pillar utilizes a seam weld similar to the rear quarter panel. Remember, the wiring loom typically runs inside this pillar, so remove it before welding.

VIN Legalities

The chassis number, or VIN, may be stamped on the scuttle panel. It's important to note that replacing this panel doesn't authorize you to stamp the new one with the old VIN. Only the DVLA has that authority. While some people might weld the old number back in, be aware that this practice is illegal.

Seam welding being applied to the A-pillar of a Mini during repairs.

Front Bulkhead Alignment Tips

The bonnet hinge brackets were intentionally left on the front bulkhead to serve as a reference point during scuttle panel replacement. If you're replacing this panel, use the bonnet to ensure proper alignment. Removing the entire bulkhead hinge bracket eliminates this reference point. Simply detach the hinge arms themselves.

When aligning the front bodywork with the doors and A-panels already fitted, especially on Mk4 and later models with rubber-mounted subframes, these subframes need solid mounting using specialized steel brackets that replace the original rubberized ones. The front panel is then bolted to it, again using the bonnet as a reference, before lining up the wings.

Front section of a Mini shell with the bulkhead visible, during the repair process.

Final Touches: Priming and Beyond

With the new boot floor securely welded in place, meticulously cleaning all connecting edges is essential in preparation for priming, seam sealing, and topcoats. Don't be fooled by the black paint on new steel panels – it's not a substitute for proper priming.

Thorough surface preparation is key to long-lasting repairs. This involves meticulously prepping all areas before priming, especially those hard-to-reach spots that might seem tedious now but will pay off in the future. Remember, attention to detail is crucial!

Newly welded boot floor in a Mini shell, ready for further repairs.
Thorough surface preparation of a Mini shell before applying primer for long-lasting repairs.

New Floor Panels and Maintaining Shell Shape

The images showcase the Heritage floor and boot panels used in this project. Given the extensive patching required, a complete replacement made perfect sense. However, it's crucial to take steps to maintain the shell's shape before removing old panels. This can involve using brace bars or even welding in temporary strengthening bars if necessary. Unfortunately, new floor panels are not currently available for earlier Minis like the Mk1 and Mk2.

British Motor Heritage full floor panel for a Mini, featuring the black factory coating.

We hope this blog post provided a comprehensive look at the body repairs involved in a classic Mini rebuild. Stay tuned for Part 3, where we'll delve into the exciting world of painting and final assembly!

Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here

Front Cover of the Keeping Your Mini Alive Magazine

Mini Sport: Your One-Stop Mini Revival Workshop

We're your trusted resource for all things Mini, ready to turn back the clock or unleash the hidden beast within your beloved car:

    • Restoration: Dream of a complete overhaul? We offer a meticulous restoration & repairs service, meticulously bringing your classic Mini back to its former glory, from a nut-and-bolt rebuild to a refresh of the interior.

    • Performance Upgrades: Craving more power and sharper handling? We have a treasure trove of performance parts to unlock your Mini's potential, whether you're a weekend thrill-seeker or a serious track warrior.

    • Motorsport Preparation: Ready to take the checkered flag? Our team's knowledge and experience will transform your Mini into a competition-dominating force.

    • EV Conversion: Envisioning a greener future for your Mini? We can guide you through the exciting world of electric vehicle conversions, ensuring a sustainable and exhilarating driving experience.

    • Fully Bespoke Creations: Have a vision for your Mini that breaks the mold? Our team is here to collaborate with you on designing and building a one-of-a-kind masterpiece.

No matter your vision, our team of passionate Mini specialists is here to turn it into reality. With our extensive knowledge and huge range of Mini parts and accessories, we can help you build the perfect Mini for your needs.

Contact us today and let's discuss how we can transform your Mini into a legend

Stay Connected with Mini Sport:

Follow us on social media for the latest news, restoration tips, project updates, and to see more classic Minis brought back to life!

With the shell stripped bare in Part 2, we are now ready to tackle the inevitable: rust and hidden repairs. Our team of experts is equipped with the knowledge and tools to bring your Mini back to its former glory. The Rotisserie: With the shell stripped clean, it gets secured on a rotating frame, also [...]
Classic Mini on ramps with the rear body panels removed, revealing the boot floor and inner structure as part of the strip down process.

Welcome to the second instalment of our Bogus 2 build series! In this series, we'll be following the entire process of rebuilding a Mini from the ground up. Today, we're diving into the exciting (and sometimes messy) world of the disassembly.

The Disassembly Begins

The first step in any rebuild is the disassembly. It's important to be meticulous at this stage, saving as many parts as possible. While some components, like the carb-type fuel tank, will be replaced with injection system parts, many original parts can be reused. Labeling and photographing every part is crucial to ensure everything ends up back in its rightful place.

Mini with original wheel arches discovered in the strip down beneath later-model Sport Pack arches.

Unexpected Discoveries

One of the interesting things about classic Minis is what you find when you start digging in. In our donor Mini, we discovered Rover Mini Special arches hiding underneath Sports Pack arches!  This kind of patchwork repair can lead to issues down the line, so it's important to address them during a rebuild.

Another discovery was the lack of inner wings behind the flip-front conversion. While flip-fronts can look cool, they can also cause serious cooling problems if not constructed correctly. Proper air flow is essential for keeping the engine from overheating, and inner wings play a vital role in directing air through the radiator.

Stripped down flip front panel from a classic Mini.

Parting Ways with the Old and Making Room for the New

With the body shell going off to the bodyshop, it's time to remove everything else. Components like the steering rack and brake servo will be cleaned and inspected for reuse. However, some parts, like the fuel lines, can be discarded if you're planning on using upgraded parts like Goodridge hoses.

The wiring harness is another area for potential upgrades. While a complete replacement loom is an option, a custom service allows for greater control. A custom loom can be tailored to the specific needs of your build, accommodating features like upgraded cables, additional power feeds, and improved grounding.

Original wiring loom of a classic Mini, before restoration.

Addressing the Rust

Rust is a common enemy of classic Minis, and our donor was no exception. The boot floor was heavily rusted, necessitating a complete panel replacement. This included the battery box, a common spot for corrosion due to battery acid and exposure to the elements.

One of the trickier areas to address was the front of the rear subframe mounting point on the heelboard. This area had rusted through completely, hidden from view by the subframe itself. Underseal can be helpful for protecting against rust, but if water gets trapped underneath it can actually accelerate corrosion.

Rusted boot floor of a classic Mini, exposed during strip down of the restoration.

The heelboard panel itself is replaceable, but it's a critical component for the car's rear suspension geometry. Precise positioning of new panels is essential for maintaining the structural integrity of the monocoque bodyshell.

Stripped down corroded area on a classic Mini where the subframe bolts to the heelboard.

The Hidden Dangers of Alloy

If your Mini has an alloy exhaust heat shield (which is typically found on models with catalytic converters), be aware of the potential for corrosion. The combination of dissimilar metals (alloy and steel), heat from the catalyst, and road moisture can create a real problem. In our Mini, we found corrosion at all the heat shield mounting points. To address this issue, we opted to replace the entire floor panel. While this may seem drastic, it's often the most efficient solution for a professional bodyshop.

Corrosion around the heat shield mounting points on a classic Mini.
Previously repaired Mini sill found in the strip down with compromised structural integrity, requiring replacement.

Unearthing the Past

Our final discovery during the strip down was a poorly executed weld job on the outer sill. These welds lacked proper penetration and wouldn't provide any real strength. Unfortunately, these kinds of bodged repairs are often hidden from view during a casual inspection. This is just the first step in our Bogus 2 build journey! Stay tuned for the next installment where we'll be following the progress of the bodywork

Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here

Front Cover of the Keeping Your Mini Alive Magazine

Mini Sport: Your One-Stop Mini Revival Workshop

We're your trusted resource for all things Mini, ready to turn back the clock or unleash the hidden beast within your beloved car:

    • Restoration: Dream of a complete overhaul? We offer a meticulous restoration service, meticulously bringing your classic Mini back to its former glory, from a nut-and-bolt rebuild to a refresh of the interior.

    • Performance Upgrades: Craving more power and sharper handling? We have a treasure trove of performance parts to unlock your Mini's potential, whether you're a weekend thrill-seeker or a serious track warrior.

    • Motorsport Preparation: Ready to take the checkered flag? Our team's knowledge and experience will transform your Mini into a competition-dominating force.

    • EV Conversion: Envisioning a greener future for your Mini? We can guide you through the exciting world of electric vehicle conversions, ensuring a sustainable and exhilarating driving experience.

    • Fully Bespoke Creations: Have a vision for your Mini that breaks the mold? Our team is here to collaborate with you on designing and building a one-of-a-kind masterpiece.

No matter your vision, our team of passionate Mini specialists is here to turn it into reality. With our extensive knowledge and huge range of Mini parts and accessories, we can help you build the perfect Mini for your needs.

Contact us today and let's discuss how we can transform your Mini into a legend

Stay Connected with Mini Sport:

Follow us on social media for the latest news, restoration tips, project updates, and to see more classic Minis brought back to life!

Welcome to the second instalment of our Bogus 2 build series! In this series, we'll be following the entire process of rebuilding a Mini from the ground up. Today, we're diving into the exciting (and sometimes messy) world of the disassembly. The Disassembly Begins The first step in any rebuild is the disassembly. It's important [...]
Original Bogus, built by Mini World

Calling all Mini fans! Get ready for a nostalgic ride as we revisit the iconic Bogus 2 project, a collaboration between Mini Sport Ltd. and MiniWorld magazine. This blog series dives deep into the story of the original Bogus and the meticulous rebuild of its successor, Bogus 2.

The Original Bogus: A Mini With a Mischievous Past

In the early 1990s, the Mini-mad crew at MiniWorld craved a project car. Inspired by the budget-friendly builds featured in CCC magazine, they envisioned a lightning-fast Mini saloon. Their creation, aptly named "Bogus," started with a not-so-perfect donor car – a theme that would continue with Bogus 2!

Despite a shoestring budget and engine woes, Bogus became a beloved figure in the Mini scene. From 1991 to 1994, it was a familiar sight at Mini events across the UK and Europe, often exceeding speed limits (ahem!) on its way to gatherings. Many Mini fans even had the pleasure (or perhaps misfortune?) of coming to its roadside rescue.

Bogus 2: Built to Last with Mini Sport Expertise

Mini Sport Ltd. stepped in to create a Bogus 2 that wouldn't share the reliability issues of its predecessor. Here's what set this rebuild apart:

  • Quality Parts: No back-street assembly for Bogus 2. we used only premium parts throughout the build.
  • Unmatched Attention to Detail: Every aspect of the car, from assembly to finishing touches, received meticulous attention.
  • Expert Craftsmanship: Our extensive knowledge and experience ensured a proper and efficient rebuild.
Bogus 2 at Mini Sport with the engine.

Building Your Dream Mini with KYMA6

Mini World's KYMA6 edition serves as a companion guide to the Bogus 2 project. Packed with valuable insights, it offers a roadmap for Mini enthusiasts looking to build their own speedy saloons:

  • Part Selection Made Easy: The guide details the specific, high-quality, off-the-shelf Mini Sport parts used in Bogus 2. This helps you avoid the hassle of sourcing or creating one-off components.
  • Navigating Regulations: Unsure about noise limitations or emissions testing for your fast road Mini? KYMA6 provided crucial information on regulations to keep your build street legal.
  • Exploring Alternatives: The guide explores alternative options for various aspects of the build, such as carburettors vs fuel injection systems..
Fully modified classic Mini, Project Bogus 2, built for performance driving on roads and tracks by Mini Sport.

Beyond Bogus 2: Inspiration and Resources

The Bogus 2 project is a testament to Mini Sport's capabilities and a source of inspiration for Mini enthusiasts worldwide. KYMA6 provides a valuable roadmap for building your own high-performance Mini.
Stay tuned for more on the Bogus 2 story, including details on the parts used, regulations, and alternative options for your dream Mini build! In future posts, we'll also delve into the exciting world of painting and final assembly – so don't miss out!

Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here

Front Cover of the Keeping Your Mini Alive Magazine

Need help? No matter the condition of your Mini's, our team of Mini restoration specialists are here to revive your Mini! From mechanical repairs to full restorations, our extensive knowledge and vast selection of approved Mini Parts ensure we have the tools and expertise to tackle any Mini problem.

Contact us today and let's discuss how we can transform your Mini into a legend

Stay Connected with Mini Sport:

Follow us on social media for the latest news, restoration tips, project updates, and to see more classic Minis brought back to life!

Calling all Mini fans! Get ready for a nostalgic ride as we revisit the iconic Bogus 2 project, a collaboration between Mini Sport Ltd. and MiniWorld magazine. This blog series dives deep into the story of the original Bogus and the meticulous rebuild of its successor, Bogus 2. The Original Bogus: A Mini With a [...]
Aaron Smith's Mini Miglia at Donington Park, to compete in the championship.

Our very own sponsored driver, Aaron Smith, has kicked off the 2024 Mini Miglia championship in style! Despite some early challenges, Aaron's talent and dedication have him firmly in the championship fight.

Mini Miglia Championship Rounds 1-2: Donington Park

The opening rounds at Donington Park were a rollercoaster ride.  Tricky weather conditions made qualifying a gamble, but Aaron secured a strong P2 starting position for Race 1. The race itself was a nail-biter, with Aaron leading at times before ultimately finishing a respectable 3rd.

Race 2, however, saw some heart-stopping moments. A slight touch sent Aaron off-track, dropping him from 2nd to nearly last place.  Never one to give up, Aaron fought his way back through the pack to finish an impressive 9th.

Cadwell Park Race Circuit ready for the Mini Miglia Championship

Mini Miglia Championship Rounds 3-4: Cadwell Park

Cadwell Park offered a more positive experience. After a pre-weekend test to ensure the car was back in top form following Donington, Aaron qualified a solid P4. Race 1 was another close battle, with Aaron finishing a well-deserved 3rd after a thrilling 4-car fight to the line.

Unfortunately, Sunday's race was canceled due to heavy rain, leaving everyone frustrated but ultimately safe.

Aaron Smith with his Mini Miglia, at the Championship
The front of Aaron's Mini Miglia, with the other competitors

Mini Miglia Championship Rounds 5-6: Snetterton

Snetterton brought sunshine and a new set of challenges. Aaron qualified 5th, but an electrical gremlin plagued the car, forcing a retirement in Race 1.  The team sprung into action, diagnosing and fixing the issue just in time for Race 2.

Starting 6th, Aaron quickly joined the top 3 battle. A dramatic turn of events saw a competitor crash, bringing out the red flag and ultimately handing Aaron the victory based on his lead position on the previous lap.  A fantastic comeback after a difficult start to the weekend!

Number 1 on Aaron Smiths Mini Miglia
Aaron Smith at Snetterton Race Circuit

Thruxton Thrills

The high-speed Thruxton circuit threw another curveball at Aaron, presenting him with the opportunity to race not just in the Mini Miglia Championship, but also take a guest drive in a Mini 7!

Mini 7: Aaron thrived in the challenge, showcasing his versatility behind the wheel. He secured a solid P5 in qualifying and delivered consistent performances, finishing P5 and P4 in Races 1 & 2 respectively.

Mini Miglia: Qualifying P2 put Aaron in a prime position to battle for the podium. While a red flag in Race 1 halted his fight for a top-three finish, he landed a P4.

Race 2 saw Aaron unleash his competitive spirit! An incredible rocket start propelled him into the lead, and despite another red flag, a safety car restart allowed him to showcase his driving prowess, ultimately securing a well-deserved P2 finish.

Thruxton proved to be a fantastic weekend for Aaron, demonstrating his exceptional talent and adaptability.

Aaron Smith with Graeme Davis' Mini 7 in preparation for his guest driving appearance.
Aaron Smith being interviewed for ITV Sport at the Mini Miglia Championship

The whole of Team Mini Sport are incredibly proud of Aaron's performance so far and are excited to see what the rest of the season holds. Stay tuned & Follow us on Social Media (Facebook, Instagram & X) for further updates and reports on Aaron's progress in the Mini Miglia championship!

Our very own sponsored driver, Aaron Smith, has kicked off the 2024 Mini Miglia championship in style! Despite some early challenges, Aaron's talent and dedication have him firmly in the championship fight. Mini Miglia Championship Rounds 1-2: Donington Park The opening rounds at Donington Park were a rollercoaster ride.  Tricky weather conditions made qualifying a [...]
Fully modified classic Mini, Project Bogus 2, built for performance driving on roads and tracks by Mini Sport.

Welcome to the first installement of our blog series inspired by the fantastic "Keeping Your Mini Alive" feature in Mini World Magazine, where Mini Sport took centre stage building Project Bogus 2 - a fast road Mini!

The Rise of the "Fast Road" Mini

This opening section dives into the rich history of the "fast road" Mini. It's a story that stretches back to the early 1900s, with car enthusiasts tinkering and upgrading their beloved machines. But in the UK, the phenomenon truly exploded in the late 50s with the arrival of affordable performance cars like the Ford 100E and, of course, the iconic Mini..

While car manufacturers envisioned families cruising comfortably in their daily drivers, owners had other plans. The thrill of beating your mates to the next corner became a national obsession! Some cars were better suited for this purpose than others, but a simple air filter upgrade, a throatier exhaust, and some sporty stripes could work wonders on any vehicle.

Plaque of Bogus 2, built by Mini Sport
Engine Bay of Bogus 2, the fast road Mini Built by Mini Sport

Race Tracks: The Proving Ground for Everyday Performance

Race tracks became a battleground for owner-drivers pushing their everyday cars to the limit. And the Mini, often the most affordable option, frequently emerged victorious. Even today, the Mini remains one of the most budget-friendly classics to modify for performance.

Rear of the fast road Mini, for Mini World's feature.

Building Your Dream: A Fast Road and Track Mini

This series is your guide to building a fast road and trackday Mini that can hold its own against many modern cars and remind them what a true "driver's car" feels like.

Stay tuned for the next installment where we'll delve into the stripping and bodywork needed to transform your Mini!

Rear of Bogus 2 before the transformation
Stripped Bulkhead of the Bogus 2 project at Mini Sport Ltd

Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here

Front Cover of the Keeping Your Mini Alive Magazine

Inspired by Project Bogus 2, you might be itching to transform your own Mini into a road-devouring beast. But where do you begin? The team at Mini Sport is here to help, offering a range of options to suit your vision, from pre-defined upgrades to fully bespoke creations!

We are your one-stop shop for all things Mini:

  • Restoration: From a complete nut-and-bolt rebuild to a refresh of your classic Mini's interior, our team of experts can bring your cherished car back to its former glory.
  • Performance Upgrades: Looking to unlock more power and handling? We offer a comprehensive range of performance parts to optimize your Mini's capabilities, whether for weekend thrills or serious track days.
  • Motorsport Preparation: Ready to take your Mini racing? We have the knowledge and experience to prepare your car to dominate the competition.
  • EV Conversion: Considering a greener future for your Mini? We can guide you through the exciting world of electric vehicle conversions, ensuring a sustainable and exhilarating driving experience.
  • Fully Bespoke Options: Have a dream for your Mini that goes beyond the ordinary? Our team can work with you to design and build a one-of-a-kind creation. From custom bodywork and interiors to unique performance modifications, we'll help you craft the ultimate expression of your Mini passion.

No matter your vision, our team of passionate Mini specialists is here to turn it into reality. With our extensive knowledge and huge range of Mini parts and accessories, we can help you build the perfect Mini for your needs.

Contact us today and let's discuss how we can transform your Mini into a legend

Welcome to the first installement of our blog series inspired by the fantastic "Keeping Your Mini Alive" feature in Mini World Magazine, where Mini Sport took centre stage building Project Bogus 2 - a fast road Mini! The Rise of the "Fast Road" Mini This opening section dives into the rich history of the "fast [...]

Steering into the Future

Mini Mpi R Range Boss Kit, compatible with Moto Lita Steering Wheels.

Classic Mini enthusiasts, a groundbreaking innovation has arrived at Mini Sport that promises to transform the way you experience your beloved car. Introducing the Mini Sport R Range Billet Aluminium Steering Wheel Boss Kits for MPi Minis. These kits are not just about enhancing the aesthetic appeal of your interior; they're about merging the nostalgic charm of Classic Minis with the cutting-edge safety and performance standards of today.

A Leap Forward with Billet Aluminium:

Crafted from aerospace-grade 7075 billet aluminium, these boss kits are a testament to Mini Sport's commitment to quality, performance, and innovation. Lightweight yet incredibly strong, they offer a perfect blend of durability and style, finished in anodised black for a sleek, sophisticated look.

Momo or Mota-Lita: The Choice is Yours:

Understanding the diverse tastes of Classic Mini owners, we've developed two distinct styles of our R Range Boss Kits - one tailored for the Momo steering wheel's 6 bolt pattern and the other for the Mota-Lita's 9 bolt pattern. This choice allows you to customise your Mini's interior to your heart's content, whether you're drawn to the sporty allure of Momo or the classic elegance of Mota-Lita.

Innovations for Safety and Performance:

One of the groundbreaking features of these boss kits is their ability to allow the removal of the MPi Mini's original airbag-equipped steering wheel without compromising the SRS system. This innovation ensures that you can enhance your Mini's interior and driving experience while maintaining critical safety features.

Key Benefits:

  • Enhanced Driving Experience: By allowing the installation of sportier steering wheels, these boss kits improve both the look and feel of driving your Classic Mini.
  • Preserved Horn Functionality: Thoughtfully designed to retain the horn push in the centre of the steering wheel, merging modern functionality with classic design.
  • SRS System Compatibility: Designed with safety in mind, these kits maintain the functionality of the SRS system, ensuring peace of mind.

Sneak Peek into the Future:

These boss kits are just the beginning. Mini Sport's R Division is dedicated to pushing the boundaries of Classic Mini performance and restoration. With ongoing developments and testing yielding amazing results, we're excited about the future of Mini Sport and the innovative products still to come.

A new Mini Suspension system fitted into the R1 Engine Conversion Mini.

Why Upgrade?

Upgrading to one of our R Range Billet Aluminium Steering Wheel Boss Kits is more than just a modification; it's an investment in your Mini's future. Whether you're an avid racer, a restoration enthusiast, or someone who simply loves driving their Classic Mini, these boss kits offer an unparalleled blend of style, safety, and performance.

Mini Sport's R Range Boss Kits.

R Range Boss kit for Momo

R Range Boss kit for Moto-Lita

Join the Revolution:

At Mini Sport, we're not just about creating parts; we're about fostering a community of enthusiasts who share a passion for the Classic Mini. These new boss kits represent our commitment to this community and to the ongoing legacy of the Mini. We invite you to join us in steering into the future, equipped with the best that modern technology and classic charm can offer.

Visit our website to explore the R Range Billet Aluminium Steering Wheel Boss Kits and discover how you can elevate your Classic Mini experience. For any inquiries or to share your thoughts, connect with us on our social media platforms - Facebook, Instagram & X or directly through our website. The road ahead is exciting, and we can't wait to journey it with you.

Steering into the Future Classic Mini enthusiasts, a groundbreaking innovation has arrived at Mini Sport that promises to transform the way you experience your beloved car. Introducing the Mini Sport R Range Billet Aluminium Steering Wheel Boss Kits for MPi Minis. These kits are not just about enhancing the aesthetic appeal of your interior; they're [...]
Rear of the Mk2 Mini Cooper restored by the specialists at Mini Sport.

The Final Reveal

As we reach the climax of our restoration journey with the Mk2 1969 Mini Cooper 998cc, painted in the stunning Island Blue with a Snowberry White roof, we're excited to share the fruits of our labor. This blog post delves into the final touches that transformed this classic Mini into a masterpiece of automotive art, ready to steal the spotlight at Mathewsons Classic Car Auction.

Front passenger side on the restored Mini Cooper painted in Island Blue.
10" Mini Wheels on a mk2 Mini Cooper is Island Blue

A Symphony of Engineering and Aesthetics

Engine Bay Perfection:

The heart of any car is its engine, and for this classic Mini, it's nothing short of a showstopper. Our Mini Sport experts have meticulously restored the engine bay, ensuring that it not only runs like a dream but also looks better than it ever did. The precision with which each component has been installed and finished makes this engine bay a true testament to our dedication to perfection.

Engine Bay Restoration, with a reconditioned 998cc Engine.

Interior: Elegance Reimagined

The interior of this Mini Cooper captures the essence of classic British motoring with a modern twist. From the iconic three-centre clock setup to the sumptuously refitted seats, every inch of the cabin has been thoughtfully restored. The new seat covers, expertly rebuilt seating, and freshly laid carpets breathe new life into the timeless design, making it a luxurious place to be.

Mini Cooper Interior, through the passenger side door.
Mk2 Mini Cooper Dashboard and leather seats.
Refurbished, classic Mini seats for a Mk2 Cooper featuring in Bangers and Cash

Attention to Detail: The Finishing Touches

It's the little details that make a big difference. The fitting of the front headlamps, rear lights, badges, and chrome trims was carried out with an unparalleled level of care. Each mirror, wheel, and tyre was chosen and installed to complement the Mini's heritage while enhancing its functionality and style. The Mini Sport plaque is a badge of honour, symbolising the quality and care taken in every step of the restoration process.

Grille of a Island Blue Mini Cooper, ready for the auction.
Rear Lights and exhaust on the Island Blue Mini Cooper
The Bangers and Cash Logo
Chrome Windscreen wipers inside a Mk2 Mini Cooper, restored at Mini Sport.
Rear Wheel and tyre on the Mk2 Mini Cooper.

Immaculate Presentation

Before its grand departure to the auction, the Mini was scrutinised from every angle, ensuring that the bodywork, paintwork, and every detail were flawless. The result is a vehicle that looks immaculate inside and out—from the pristine engine bay to the spotless boot and the stunning interior.

Reconditioned 998cc Engine, in a Mini Cooper.
Rear of the classic Mini Cooper painted in Island Blue
Inside the boot of an Island Blue Mk2 Mini Cooper.

Exclusive Insights: Bangers and Cash Praises Mini Sport

Don’t miss the exclusive video from the Bangers and Cash: Restoring Classics team, where they express immense admiration for the restoration quality of this Mini Cooper. Watch their heartfelt praise and see why our restoration stands as a jewel of classic car excellence. Watch the Video

Ready for the Spotlight

As the Mini Cooper makes its way to Mathewsons Classic Car Auction, it's not just going to a new home—it's entering the annals of classic motoring history. This Mini is a shining example of how passion, expertise, and attention to detail come together to restore not just a car, but a legacy.

Stunning Mk2 Mini Cooper, restored by the Mini Specialists at Mini Sport.

Join Us at the Auction

Experience the excitement firsthand and consider bidding on this beautifully restored classic Mini Cooper at Mathewsons on May 2nd. For more details and to view the auction listing, click here.

Morris Mini Cooper boot badge, fitted onto the Bangers and cash Mini.
Locking fuel cap, on an Island Blue Mini Cooper restored at Mini Sport.

Join us in celebrating the rebirth of this motoring icon at the upcoming auction on May 1st. For those who have followed this journey, thank you for being a part of this incredible project. For potential buyers, this is more than an investment—it's an opportunity to own a piece of automotive art, meticulously restored by Mini Sport.

Bangers and Cash, collecting the Mini Cooper to be taken to auction

Stay Connected

Follow us on social media: Facebook, Instagram & Twitter for more updates and behind-the-scenes content from Mini Sport. Witness the passion and precision that go into every one of our projects and share in the excitement of classic car restoration at its finest.

The Final Reveal As we reach the climax of our restoration journey with the Mk2 1969 Mini Cooper 998cc, painted in the stunning Island Blue with a Snowberry White roof, we're excited to share the fruits of our labor. This blog post delves into the final touches that transformed this classic Mini into a masterpiece [...]
Mini Sport R Range Radius Arms

The Cutting-Edge R Range Billet Aluminium Radius Arms Revolutionising Classic Mini Performance

The journey of enhancing Classic Mini performance takes a monumental leap with the unveiling of Mini Sport's R Range Billet Aluminium Radius Arms. Born from the innovative minds at our R Division, these radius arms are a blend of sophisticated engineering and a profound affinity for the Mini, offering a transformative approach to handling and performance.

Innovation at the Core:

Our ethos at Mini Sport R Division centres on harmonising the rich heritage of the Classic Mini with cutting-edge automotive advancements. The R Range Billet Aluminium Radius Arms are the embodiment of this philosophy, utilising aerospace-grade 7075 aluminium for an optimal balance of lightweight strength and enduring durability. This material choice is critical, offering the toughness needed to propel your Mini's handling and agility into uncharted territories of performance.

Close up of an R Range Radius Arm, by Mini Sport.

Technical Mastery Unleashed:

Precision is key in the development of the R Range Billet Aluminium Radius Arms. Through meticulous CNC machining, each arm is crafted to achieve a weight of just 3.32kg, including the integrated spindle and stub axle. This weight reduction from the standard 5.25kg cast arms significantly diminishes unsprung mass, directly translating to enhanced agility and response on any terrain. Furthermore, each arm is engineered to incorporate a world-first 1° of Negative camber built into the stub axle, optimising rear-end handling for a sharper driving experience.

Mini Sport R Range Radius Arm drawing

Ready for Maximum Attack

Our radius arms come fully equipped with cutting-edge stub axles and pivot pin kits, and are enhanced with needle roller bearings, which offer superior precision and durability over traditional bushings. Designed for a perfect fit with coil spring suspension systems, they are delivered ready to install. This ensures immediate improvements in handling and responsiveness, crucial for enthusiasts who demand the best from their road and track experiences. Excitingly, we are also close to launching the Knuckle Joint version, which will be compatible with the traditional Mini rubber cone suspension setup. Keep an eye out for updates!

Pair of R Range Radius Arms, compatible with coil Suspension

Durability Meets Design:

Designed using state-of-the-art CAD/CAM software and stress-tested for peak reliability, these radius arms not only promise exceptional performance but also boast a visually striking anodised Orange finish, exclusive to the Mini Sport R Range. This not only enhances the vehicle's aesthetic but also signifies the arms' quality and the innovation behind them.

The Next Generation of Mini Suspension:

These radius arms signal the advent of a revolutionary suspension system meticulously devised by our R Division. Following extensive testing and remarkable outcomes, this forthcoming system is keenly awaited by the Mini enthusiast community, promising to redefine what's possible in Classic Mini handling and performance. Register your interest today to be among the first to experience its transformative capabilities!

A new Mini Suspension system fitted into the R1 Engine Conversion Mini.

Choosing R Range - A Commitment to Excellence:

Opting for the R Range Billet Aluminium Radius Arms is a declaration of your dedication to pushing the boundaries of what your Classic Mini can achieve. It's an investment in cutting-edge design, superior craftsmanship, and a lineage of performance that's second to none. Backed by Mini Sport's legacy of innovation, these arms are more than an upgrade—they're a new benchmark in Mini performance.

The R1 Engine Conversion Mini, on track at Curburough.

Developed & tested on our R1 Race Mini.

Stay Tuned:

The evolution of Classic Mini performance is underway, and with the imminent launch of our full suspension system, the excitement is just beginning. We invite you to join us on this exhilarating journey, stay connected for the latest updates, and be among the first to elevate your Mini's performance to new heights.

The R Range Billet Aluminium Radius Arms signify a groundbreaking advancement in the pursuit of superior Classic Mini performance. They represent not just a product, but a new era of customisation, performance, and style for Mini enthusiasts. As we prepare to unveil our comprehensive suspension system, your Mini stands on the brink of a transformation that will redefine its legacy on the roads and the tracks.

Stay engaged with Mini Sport for the upcoming launch, and be part of the revolution that's setting a new benchmark in Classic Mini performance. Follow us on Facebook, Instagram, and X (Twitter)

The Cutting-Edge R Range Billet Aluminium Radius Arms Revolutionising Classic Mini Performance The journey of enhancing Classic Mini performance takes a monumental leap with the unveiling of Mini Sport's R Range Billet Aluminium Radius Arms. Born from the innovative minds at our R Division, these radius arms are a blend of sophisticated engineering and a [...]
Painted Shell of a Mini Cooper Restoration, painted in Island Blue and Snowberry White Roof.

Breathing New Life into a Classic: The Engine, Wiring, and More Behind the classic Mini Cooper Restoration

Welcome to the latest instalment of our restoration journey in collaboration with the hit television series, Bangers and Cash: Restoring Classics, about the Mk2 1969 classic Mini Cooper 998cc, painted in the breathtaking Island Blue with a Snowberry White roof. This chapter takes us deep into the nucleus of the restoration process, where we meticulously rebuild the engine and gearbox, craft a new wiring loom from scratch, make strategic upgrades to the brakes and suspension, and conduct a thorough refurbishment of the carburettors. It's a journey that showcases the unparalleled precision, expertise, and passion Mini Sport brings to this ambitious project.

A Mini Gearbox built, for the Bangers & Cash Mini.
A classic Mini Engine Block, as part of an Engine rebuild.

The gearbox's restoration mirrored this philosophy. With a focus on reliability and a smooth driving experience, we replaced worn bearings and seals, recalibrated the gear ratios for optimal performance, and ensured that the rebuilt gearbox would deliver a seamless transition between gears, enhancing the Mini's drive-ability and joy.

The built Engine for the Bangers and Cash Mini.
A built Mini Cooper Engine.

Electrifying the Past: The Wiring Loom

The electrical system often represents a significant challenge in classic car restoration, primarily due to age-related wear and outdated technology. Our Mini Cooper's original wiring was a tangle of decades-old issues, necessitating a fresh start. John, our expert in automotive electrics, undertook the meticulous task of building a new wiring loom. This wasn't just about replacing old wires; it involved construct a completely new wiring harness that would respect the Mini's heritage while infusing it with with modern durability and reliability. The result is a harmonious blend of the past and present, ensuring that every electrical component works flawlessly.

The Bangers and Cash Logo
Building a Mini Wiring Loom, for a Mini Cooper restoration.
Mini sport Braided wiring loom
Battery fitted to the boot of a Mini Cooper.

A Modern Twist on Classic Brakes and Suspension

In updating the brakes and suspension, our goal was to respect the Mini's heritage while preparing it for the demands of modern driving. The original braking system was replaced with Mini Sport’s alloy brake callipers, designed and machined in-house. These callipers, combined with larger discs, provide a significant improvement in braking performance and heat dissipation, crucial for both safety and driving pleasure.

Front and rear subframes, built with genuine suspension cones and alloy calipers.
Mini Sport Blue Alloy Brake Caliper, fitted onto a subframe.

The suspension's transition to a dry system was equally strategic. By replacing the Hydrolastic system with Mini Sport Adjusta Ride and Moulton Suspension Cones, we achieved a ride that's both faithful to the original feel and enhanced for modern roads. This upgrade ensures the Mini handles with the agility and comfort expected of today's vehicles, without sacrificing its classic character.

Rear subframe, fitted onto a Mini Cooper shell painted in Island Blue.

Breathing Life: The Carburettors

The carburettors are where fuel meets air, and magic happens. Our restoration process for these crucial components was not just a task—it was a mission. Each carburettor was dismantled, with every part cleaned, inspected, and refurbished or replaced as necessary. By fully reconditioning and rebuilding these vital components, we've ensured that the Mini Cooper's engine will sing once again. The restoration of these carburettors focused on achieving the perfect mixture and flow, optimising fuel efficiency, and ensuring that the engine's response to the throttle is both immediate and smooth. 

Remanufcatured Carburettors fitted onto a classic Mini Engine.

The journey of restoring this Mk2 1969 Mini Cooper 998cc is testament to the dedication, expertise, and passion that defines our Mini Sport team. Each component, from the engine to the wiring loom, has been treated with the utmost care, ensuring that the essence of this classic car is not only preserved but enhanced. Ensuring this amazing Mini not only celebrates its rich history but is also primed for creating new, unforgettable memories.

Follow us on social media for continuous updates on this exciting journey. Together, we're not just restoring a classic Mini Cooper; we're redefining its legacy for the modern era.

Engine fitted into the Bangers and Cash: Restoring Classics Car.
A classic Mini 998cc Engine, fitted.
Filming of the Mini Cooper S, featuring on Bangers and Cash: Restoring Classics.

Ready to make your Mini dreams a reality? Reach out to our team today. We're not just mechanics and engineers; we're enthusiasts like you, committed to preserving the Mini's legacy.

Contact us: sales@minisport.com

Breathing New Life into a Classic: The Engine, Wiring, and More Behind the classic Mini Cooper Restoration Welcome to the latest instalment of our restoration journey in collaboration with the hit television series, Bangers and Cash: Restoring Classics, about the Mk2 1969 classic Mini Cooper 998cc, painted in the breathtaking Island Blue with a Snowberry [...]