Damaged Classic Mini block hits the machine shop... Can it be saved?

Our 1965 Mini Cooper S may be bored, but we've never been more engaged. This week Davin heads over to Thirlby's Machine Shop to get this 1275cc British monster cleaned up and nearly back to its original shape. We had some concerns about what we unearthed last week on our block, but it's up to the boys at the machine shop to diagnose how severe things might be.
Thanks to our sponsor RockAuto.com. RockAuto.com is an auto parts retailer founded in 1999 by automotive engineers with two goals: Liberate information hidden behind the auto parts store counter (by listing all available parts, not just what one store stocks or one counter-person knows), and make auto parts affordable so vehicles of all ages can be kept reliable and fun to drive. Visit www.rockauto.c... to order auto parts online 24 hours a day, 7 days a week, and have them conveniently delivered to your door. Need help finding parts or placing an order? Visit our Help pages for further assistance!
Subscribe to our KZbin channel for new videos every day! bit.ly/HagertyY...
Visit our website for daily automotive news, cars stories, reviews, and opinion: www.hagerty.co...
Stay up to date by signing up for our email newsletters here: www.hagerty.co...
Follow us on social media:
Facebook | / hagerty
Instagram | / hagerty
Twitter | / hagerty
If you love cars, you belong with us. Hagerty Drivers Club is the world’s largest community for automotive enthusiasts. Members enjoy valuable automotive discounts, exclusive events and experiences, roadside service created specifically for collector vehicles, and a subscription to the bimonthly Hagerty Drivers Club magazine. Join Hagerty Drivers Club here: www.hagerty.co...
Like what you see? Watch our other series including:
Redline Rebuild | Engine Time-lapse videos from start to finish bit.ly/RedlineR...
Barn Find Hunter | Tom Cotter searches the country for abandoned cars bit.ly/BarnFInd...
Chip Foose Draws a Car | Reimagining popular cars with new designs bit.ly/HagertyC...
Contact us:
Suggest and feedback - [e-mail]
Press inquiries - [e-mail]
Partnership requests - [e-mail]

[@ianmcgee9945]

If you haven't got it already, try to get a copy of the book "Tuning The A-Series Engine" by David Vizard. It will tell you everything you need to know.

[@Smoutification]

That was my bible growing up. I lived close to Ripspeed in London and bought it there. I was also lucky to have the mini centre over in Barnet too. I think pretty much everything was replaced on my first mini. My dad had Coopers in the 60’s so had a lot of experience with them.

[@monono954]

That man is a legend. I have MANY of his books.

[@jasonpeters9390]

Yep that was my bible made some pretty quick mini 1000s back in the day just by going to scrap yards later made a very quick 1293 witch would leave xr3i behind

[@miketeeveedub5779]

I remember watching an episode of Jay Leno's Garage, where Jay said many many of the English car manufacturers used green paint simply because they were able to procure high quality paint cheaply from local military depots. That explains the militaristic green used on the Cooper's block.

[@TornadoCAN99]

I've heard the 1275 cooper S blocks were usually red.

[@johnluna9915]

Is that where the term British racing green came from?

[@JohnThomas-vb9se]

I miss my local machine shop. It was kinda like “Cheers”. Owner retired and everything sold at auction.

[@catlee8064]

Many, many, MANY moons ago, i got a 1275 engine for the mini van i had at the time. Ported head, twin 1 1/2 inch SUs, K&N filter, front discs (rotors) conversion, free flowing exhaust. I thought i was a proper racer in that thing, for about a week until a tyre blew while i was "driving with vigour" down a country road, ended upside down in a ditch. Total right off and 1 week in the hospital for me !

[@Jesse-B]

Ouch! Glad you're here to tell the tale.

[@catlee8064]

@@Jesse-B Thank you sir!

[@SMlFFY85]

Lesson here is, don't drive like a dickhead.

[@catlee8064]

@@SMlFFY85 Yeah because we all drove like nuns at 18 yrs old.

[@roelfkromhout]

@@SMlFFY85 no, the lesson is don’t cheap out on tires.

[@marshalldouglas6048]

Your camera work of the machining in slow motion is amazing. Really enjoy watching your projects

[@jeffplant3]

Well done! No mistaking that that colour is green! Awesome that the block has been saved. Can't wait to see the assembly on this one!

[@thatdudeinorange2297]

Its a Land Rover colour!

[@daranleighton9813]

Good to see the original block saved. The green looks great! 😎

[@johncottrell2464]

I have a 71 MG midget with the 1275 as well. and I'm super excited to do a build on it with some high compression pistons, and a good head job. This is super helpful and seeing how the block is torn down, and cleaned. Keep the videos coming!

[@SeanKStephens]

I enjoy the camera work and the projects you select. I especially like how he makes sure to credit every other person who is involved with the project. Lately I've been missing the old days when I did this kind of work. It's great to see how it has changed and how much of it hasn't.

[@andrewriley635]

I'm from the UK and have owned a few Minis, including a 1275 GT Clubman (look it up) and I think that is possibly the vilest colour known to man! The must have found stocks left over from the war...

[@ZEPRATGERNODT]

My daughter regurgitated that color somewhere in time span of her first year.

[@1chish]

Noooo ... THE vilest colour was what was known as 'Putrid Yellow' which was used on the A+ 998 blocks. Just BMC keeping a tradition going! 😂

[@MacBob]

@@1chish Maybe that was the same yellow that they used to paint the outside of the 1980 Clubman Estate i learned to drive in 🤑😄

[@1chish]

@@MacBob I thought everything was 'beige'? 😂 Although my '78 Mini 1000 I am restoring started life in a rather garish Java Green!

[@robertlambert5299]

Another great video! Thanks Davin and crew.

[@rdyer8764]

Redline-Update-Day is my favorite of the KZbin week!

[@tenlittleindians]

Looks a lot like a motor in my basement that I took out of an old Austin Healey Sprite. Mine still has the piece on the crankshaft for the hand crank start. I think they were just grabbing motors off the Morris Minor assembly line to use in early Sprites as the Minor had a hole for a crank start but I don't recall any Sprites with that hand start backup.

[@secretagentbloke]

I think all Sprites used an A series engine like this

[@tenlittleindians]

@@secretagentbloke Like it but different CC's depending on what year. The older ones are smaller with less horsepower. Maybe the bigger CC's got a little hard to crank by hand?

[@robertwoodliff2536]

I think the A35 had the A series engine..Hub Nut has a nice 20 mins on the A series..

[@jpkatz1435]

Yes! "Pick up a can of paint and spray something." Words to live by, thankyou!

[@Me-zo8yc]

So satisfying to watch

[@rogjackson]

That green is butter. I like it.

[@secretagentbloke]

Good old BMC mushy pea green 👍🏻

[@stephenmoxley3004]

This is a really cool project. Looking forward to seeing the finished product.

[@lukasraus3391]

every project from Hagerty is cool :D

[@kyleforeman4543]

Sweet deal on saving that massive blk.lol.the good old ground color, liv that Machine Shop,very talented who runs those machines..no oops in their process..another great video from the guys behind the scenes

[@RedsGarageUK]

Nicely saved! Green isn't really my colour, but I gotta admit... that looks good.

[@malcolmmoy]

Factory colour

[@MH-ev3wr]

It’s an engine for chrissakes.

[@RedsGarageUK]

@@MH-ev3wr Um, yes?

[@billyazprospector]

I love the machine shop, such a beautiful process!

[@mariosnikolaou5212]

Nice result!!

[@scottimusgarrett15]

I love that green, actually. That's a right proper British racing green!

[@GTE_Channel]

Green is the best colour for a Mini Engine 👍

[@Damien.D]

Nah, it's not a machine shop, it's a wizards guild...

[@thatdudeinorange2297]

Love that they think this will stop it from puking oil. Not unless gearbox gets new bushings in the diff housing, otherwise the driveshafts will continue wobbling around..

[@lateefcarrere1649]

That's a rich, deep moss green paint job. Probably worth another 2 HP😁

[@ronlynch7744]

Awesome vid of boring the cylinder. 😎👍🇨🇦

[@larrybair8074]

Always enjoyable watching.

[@iainbarker1815]

If you take the time to read the factory workshop manual for the original Cooper S, you’ll see it says never to chamfer the top of the bores on an A-series block.

[@wwz1100]

Дэвин, результат прекрасный, как всегда.

[@Carguy-sp8xj]

Thank you for reminding me. Ive got a ton of projects that I want to get done. Ive got a leaf blower from the 90’s that I’m rebuilding and I’ve got a set of valve covers for a Ford 460 that I’m painting and I also got a truck that I’m currently trying to get back on the road. I’m saving up my money for a classic car or truck. Nothing special or fancy just something to have as a summer car and go to car shows with

[@victorbitter583]

I hope that project goes well for you. cheers.

[@joelpalmer]

All the videos are terrific! one correction. It is oil galley, not gallery. You will never find a listing for "gallery plug". It is always "galley plug". Carry on !

[@andoletube]

Try googling it then... Plenty of listings for Oil Gallery plugs. The terms are used interchangeably in modern times, regardless of galley coming first.

[@Jesse-B]

Loving this build.

[@dwiananto7519]

Thank you for sharing your knowledge about maintenance and repair of the machine 🛠⚙ i like this video 👍💌🇮🇩

[@bozodog428]

Shaping up nicely.

[@paulprescott7913]

Great stuff , another A series saved. And better than when it came out of Longbridge.

[@patrickcannell2258]

Now this is a real Mini you are doing! Not a BMW "Bini" we have now!

[@BrinToo]

Looks like you matched up the British Leyland engine green well. Looks just like my Mini back in the 70s!

[@1chish]

Well nearly. The green was a BMC colour called "British Standard Middle Bronze Green (BS 223)". BL used other colours (yellow for 998, black for 1275)

[@thatdudeinorange2297]

@@1chish black on 1275's was a 70's thing. And red 😭 at the end!

[@asarand]

It's kind of shiny, but it looks like an olive drab. Interesting color for an engine.

[@iainbarker1815]

It’s the correct color. BMC mid-bronze green.

[@jasondk5127]

Our customers bring in doughnuts and bagels all the time. They know where are hearts are...our stomachs😛😄😁😆

[@1chish]

Just caught up on this series Mr Hagerty and picking up on your surprise earlier about bolt sizes these were all 'Imperial' or what you call 'Freedom' fraction sizes. The threads were either UNC or UNF although the brute of a thread on the clutch end of the crankshaft and the crankshaft pulley bolt thread are Whitworth profile (if not BSW size). Metrication had not kicked in by 1965 and even when it did the legacy engines and gearboxes remained 'Imperial' sizes. So don't be surprised that your spanners (wrenches) are fitting my friend. They were US sizes and threads! Apart from that bit of geekery just wanted to say what a superb and respectful job you are doing. That engine and gearbox (indeed the car) were revolutionary in the '60s. I would suggest you spend some time just exploring how Issigonis and his engineers fitted a very good gear set into the 'sump' of that engine. That particular gearbox is called a 'Remote Change' and was considered the best for the faster Minis.

[@jonathanowen6147]

Love the green!

[@claycoates5056]

Looks Good But i I'm Not Green With envy

[@blade-vk]

I do have a really good question, that will also be the answer to a lot slow processing like this baking. Are you familiar with Laser cleaning? A powerful one of course, 1kW or 2kW laser? These machines clean like magic all grease, stains, paint and etc. If you haven't heard will you consider buy one of those clean machines? The process is lovely to watch, the result are more than satisfying!

[@jimclarke1108]

I owned a mini cooper s back in the day, rebuilt the engine in my little shed ,after assembling the gearbox/diff, wouldn't fit out the door🤠

[@Friedbrain11]

British racing green color is sweet!

[@tavarisjones551]

lol... he clearly doesn't like the green :) Have to say that I'm not feeling it either, but still enjoying the build videos.

[@PhillyDee215]

💥Only if I had that machinery in my home garage😎

[@taylormurphy5221]

Sprite midget green, nice!

[@malcolmmoy]

I'm sure the head has oversized valves, they are definitely not standard. I'd also worry about removing any metal (chamfering) between the 2nd and 3rd bores as that's always a failure point.

[@jamesdiehl8690]

You could have gotten a Predator engine at Harbor Freight for less money! 😀

[@dot73]

This is real America.

[@rgbigdog]

That green looks like Army OD Green.

[@andrysupps2249]

Настоящие профессионалы! 👍

[@monono954]

Real missed opportunity not including some machining shots while the block was being decked.

[@sonyhk3824]

Great job guys love it 👍

[@d13cab]

Good Choice in colour just like original early bmc colour 👍

[@billbeyer657]

No sleeves! I can't bear to watch that horror show again. I remember that color green from when I used to change my kid's diapers.

[@THROTTLEPOWER]

Great vid...... 👍👍👍

[@Cartier_specialist]

Looks very much like Army green.

[@hotpuppy1]

Unless the gouge goes to a water jacket hole, it likely would have been OK anyway as little as was left after decking. A soft head gasket would seal. That engine doesn't have huge compression. The rings don't go that high in the bore.

[@braulioblebadal1937]

Son un gran ejemplo de buenos mecánicos. Saludos.

[@donaldk.macbaird5248]

We call that Baby Sh$t Green

[@exothermal.sprocket]

The music is interesting, sort of a 1980's feel. Beats all the electronic dubstep garbage that's taken over the social media it seems.

[@victorbitter583]

Don't get me started on the Chipmunks on helium and the synthesized pan flute and all the other horrendous so called music that is destroying these platforms. You have to expect it on some channels but when someone's target audience is 40+ male and they are using it, it shows a complete lack of respect on that creators behalf in my opinion.

[@exothermal.sprocket]

@@victorbitter583 Thanks for being level headed about this stuff. Honestly I don't believe even the young generation likes that chipmunk on helium dubstep electronic synthesized garbage. They've just been made to believe they like it through mind numbing repetition and exposure.

[@victorbitter583]

​@@exothermal.sprocket My absolute pleasure, mate. It drives me mad. Apoplectic at times. It just beggars belief. It must be being pushed by some psycho with some abhorrent plan for world domination or something lol. cheers.

[@exothermal.sprocket]

@@victorbitter583 Well I'm not certain about that, but what I am certain about is that a few large music corporations control just about all of it, and through their desire to never take risks (ie. lose money), they only pump out in the mainstream the stuff they can generate cheaply. And all the musicians doing great stuff with actual talent are never heard from.

[@Me-zo8yc]

I liked it too, the previous Mini vid music was even better

[@chrisr8653]

Ahha that green isn't the best buddy I would of kept with chrome an red ;) that would be nice N slick looking. But it def looks better then before buddy. Great job n work

[@ezequielpiacenza3776]

Cómo me gusta ver trabajar a las alesadoras de cilindros y bancada 😶✌️🤙👍

[@RoninDosho]

Nice….as usual 👍🏼

[@jasonvenegas8264]

I love it I love it I love it

[@Jo-gb9iu]

Мастерня конечно классная, сам бы в такой работал!)

[@roadmantop3769]

Love this ❤️

[@ravennexusmh]

taking it to 1312cc eh, big power haha

[@inkshop963]

hope he goes to flat top high compression pistons!

[@thatdudeinorange2297]

In the power per litre/cubic inches its quite possible it beats loads of V8's?! Wont matter much as this little car beats power to weight ratio of many cars. And it didnt come with 12 cupholders as european people has understood a car is a car and not a mobile restaurant 😉

[@ditzydoo4378]

Bake the Mini-Block... Not the Mega-Bagel... 0~o the color is British Racing-Green. very classic that.

[@irritablearchitect]

The siamesed port on 2-3 in these heads is a problem with tuning. David Vizard covered this in a lengthy seminar many years ago and he's convinced that there isn't a cam out there that can accomplish what the demands are of the engine.

[@Smoutification]

There were aftermarket 4 port heads available.

[@thatdudeinorange2297]

@@Smoutification For the two cylinder engine? Yes such an engine was tried for the Mini. Joking aside know you mean 8-port head for the four cylinder engine.

[@Smoutification]

@@thatdudeinorange2297 Hehe. Yeah sorry. I meant 8 port such as the Arden one.

[@ezequielsilva2709]

Muito bom ver um profissional em ação

[@mikecorleone6797]

I’m hoping one of these days you guys manage to get your hands on a subaru 360.. working on mine feels like a hagerty episode lol

[@user-vr6kd8nk8w]

Good time of day. My name is Alexander, I'm from Russia, cool videos. I wanted to know how much you will have to repair the ep6 motor. Thank you in advance.

[@moneywatchofficial1714]

Great 1

[@matthewhelton1725]

British Racing Green and British "Pitch Green"... uniquely British. Not "colours" anyone would choose in a lineup, but pleasing nonetheless.

[@FourDollaRacing]

It's "the most interesting green" because it's a post-war tractor engine....

[@flypawels]

👍

[@Engineerd3d]

Man that looks like Mary Jane green. I guess it's a BRG derivative! Mon!

[@maldo72]

damm that's some green color

[@twrecks4598]

what caused those crazy gouges btwn the block and the head? Someone run into the block with a forklift or something?

[@bogusbits6810]

I'd bet that the engine machining and paint cost far more than did the original car!

[@matthewcalifana488]

Reminds me of MG minget

[@ALPMotor1263]

Hallo from Indonesia

[@patrickdombrosky6951]

Think you guys could give an estimate or how much it would cost to bore/sleeve/plane the surfaces on these builds? It'll help us project owners gauge about how much to expect to spend on things. Thanks!

[@victorbitter583]

Having worked in a machine shop I can tell you that the answer is always "it depends". It depends on many things, all of which are unknown until the machinist has assessed all of the parts. If you want a quote, take everything you need done down to a machine shop and ask them. Also, the 2 companies mentioned in this vid (the machine shop and the paint shop) are probably either doing this work for free or for cost.

[@ALPMotor1263]

Hagerty best mecanic rebuilt

[@fixedguitar47]

Look kids, things are changing, if you like internal combustion engines I suggest you take good care of the one you have. Why do I think this? “Blue Oval City” And The first three nuclear reactor power plants being built in the United States since 1979. I work in automotive manufacturing. Sooner then later you WILL be driving an electric car wether you like it or not.

[@dav1dbone]

It would be interesting if you could tell us what the cc capacity has changed over the original 1275? You removed material from the head area and cylinder bores, so maybe still the same, more or less?

[@johnrebus1641]

If the bore is now 40 thou over ( 2.82" or 71.63mm) the displacement will be 1310cc, so about a 37cc increase over the standard 1273cc. Removing metal from the top deck surface will increase the compression ratio but won't alter the displacement. I quite like the green, it's a lot more interesting than Chevy orange

[@Garaj_Mekan]

İzlemeden beğendim 🤙🏻

[@jayczyzyk9707]

What year is the engine ?

[@chuckwhitson654]

Looks like lawnmower pistons and rods ( 2 1/2" bore x 3" stroke?) Haha. 1"& 7/8" valves? Lol again

[@thatdudeinorange2297]

Where did you pick up those valve and piston sizes? Havent seen or heard those valve sizes before.

[@autka_me]

Love that BRG color on the block. What will be the head gasket material? Copper?

[@victorbitter583]

That is not BRG. Not even close.

[@ellieprice363]

Thanks for the interesting engine update. That sh...ty green must have been the original color. Can’t think of any other reason to cuss a fine little engine that way. Decking the head and block will raise the compression ratio. Wonder if it will need premium gas?

[@thatdudeinorange2297]

This particular engine didnt have vacum advance for the ignition so octane needed for this engine was 98 at a minimum, preferably over 100 octane, but if thats measured in RON or MON is beyond me. Edited my schpelling mischtakes 😉

[@ellieprice363]

@@thatdudeinorange2297 If the mechanical advance is properly set vacuum advance is not needed, although it does help fuel economy at part throttle. I seriously doubt that 98/100 octane fuel was available to the general public when this engine was designed or even now. It will be interesting to see what fuel Davin uses when it’s fired up.

[@skylinefever]

I think 93 octane R+M/2 gasoline is about 95 RON, but I could be mistaken. I'm guessing 98 RON was what you are thinking, I heard that was common in Europe. I have heard that if some engines have more combustion chamber squish, they can handle a little more compression without demanding more octane. That might happen if the block is heavily decked and the head gasket is thin. This is why some guys go to great lengths to get "Zero deck" on engine builds.

[@thatdudeinorange2297]

Dont know about today but a year ago 98 octane was available for most of european cars, such as these Mini's which had 9,75-1as factory spec'd compression ratio. And yes Ron and Mon are different ways to measure octane rating. Sorry but couldnt remember which is used where. But vaugely remember 99 octane or even higher sold here in Scandinavia in the 1970's

[@neophobiagarage1845]

👍👍👍🥰

[@המכונהשבאופנוע]

Pros

[@diegoramdhani2799]

What actually happens with the cars after the redline rebuild is finished?

[@metricstormtrooper]

Should get a Morris 1100 block (long stroke 1275) bore it out to get 1410cc.