Classic Mini Workshop - Project Sprout Pt.18 Sill Finished & Door Hinge Repair

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Here it is, the new project Mini. Found on E-bay but I lost the auction only to later find the higher bidder messed the seller around so it was offered to the next highest bidder...... Me. The Mini is a 1997 Rover Cooper MPI and has been off the road in a garage since 2007! It's what some might call a barn find.
In this update I refit the outer sill and weld in place. I remove the front door hinge that had broken studs and replace

[@phillipwood9833]

I used to work on WWII jeeps and we welded up holes in the bodywork by using a piece of PhosphorBronze behind the hole, Tried copper but the heat from the weld distorted it and we found the PB let us weld up bigger holes as it dissipated the heat better.

[@fordyootbling2189]

Mig welding upside down.. not for the faint-hearted. Good vid. Many thanks.

[@paulrichter3081]

Top video, nice bit of lateral thinking the hinges, tidy welding

[@thedjse]

Superb work Keith! That welding looks amazing!

[@classicminiworkshop]

Thanks mate

[@LoneStarMini]

you seem to have wonderful patience.. before I figured out to take my time, I've snapped many of bits trying to drill out threads.... well done

[@markharris7662]

It is looking solid. Not on bad nick for a mini.

[@ClassicCarCave]

Keith, Nice job on the hinge bolts saved a few quid apart from the hassle of lining the door gaps up, The outer sill looks really neat and top quality fit, Cheers Dave

[@minitom7772]

I did the same with my hinges Keith, picked up some 1/4” unf bar and some M6 bar too. Ended up drilling the stud out, re-tapping to M6 and went metric in the end. Must admit I was screaming at my screen watching you try it lol. Got there in the end though pal

[@BMCWorkshop]

Looking good Keith. The M Machine sills are great

[@no66]

Nice one. Following as I have to replace the sills on my 72. Hoped you were going to show more of the rear lip that goes over the sill at the rear and welding up the lip to the flitch panel. May be show when you do the other side?

[@moran68]

Lovely job ! 👍

[@markpiper8082]

I could of told you they had thread in studs 🤣😂🤣. When i rebuilt mine no matter how much i got burnt i loved seeing new steel on the car

[@steven-vn9ui]

"The weld won't actually stick to the copper", oh, Damnit! Thanks for the upload Keith - coming along nicely mate. On a side note that jacking point is quite handy actually, wish cars nowadays had something more sturdy and made for the job. I changed the rear springs on my car today (fiat 500) and faffed around for ages finding a secure place to jack and put the stands under (the sills on the 500 are not load bearing so can't just slap a jack on them willy nilly). I hate scratching up finishes so some old carpet was used and plenty of wax oil on the rear beam and spring cups. Then it rained (again).

[@classicminiworkshop]

LOL, Thats exactly what I was thinking!

[@chrisdowns9828]

Hi, great video. Did you get around to using the spot welder for the seam? I have one and was wandering how to best ensure there is sufficient penetration on the spot weld?

[@classicminiworkshop]

I practiced with a few cut off's and then tried to rip apart to see how strong it was. After a few welds you get a feel for the welder but generally if the metal is clean and the tips are clean and cut well then the weld if perfect every time

[@michaelo85]

Keith what welding wire do you use?

[@stephenmorgan8255]

What did you paint the back of the panel with to stop it rusting straight through ...

[@classicminiworkshop]

Upol #2 Weld Through Primer. Works very well

[@jaggass]

Is Project Sprout in Almond Green?

[@classicminiworkshop]

Yes, pretty sure it is but not checked the paint code yet