Dangerously rusted 2009 R56 mini rear subframe replaced, fuel tank was just hanging on- check yours!

Welcome back to the channel, today with the help of Chester the cat I'm changing the very rusty and dangerous rear subframe on our 2009 R56 mini cooper
The subframe rust had been advised on the previous MOT test but it was far worse than we thought and really shouldn't have been on the road, the fuel tank mounting straps bolt onto the subframe in two places, one had completely detached, the other wasn't far behind and wouldn't have lasted much longer (a bad road with a few pot holes could have been disastrous)
I had a few issues along the way including stuck brake pipes and antiroll bar drop links as well as the wrong number of bolts supplied by the main dealer but we got there in the end and I'm really happy with the results

[@johndumarney1630]

Nice to see the new mini rusts just like the old one

[@paulsprojects1]

its quite common on a lot of cars these days apparently

[@dewiroberts8591]

It's surprising how bad the subframe was,and a surprise that it passed the last MOT. Another great video Paul.

[@paulsprojects1]

yeah it wasn't great but a bit better now, cheers Dewi

[@neiljarvis8911]

My Mrs has a 34k mile 2004 cooper, I have to say that's completely put me off doing that 😂. All credit to you, you did a grand job!

[@paulsprojects1]

thanks for the kind reply, the job would be a lot easier with a two poster ramp for sure

[@paultaylor9652]

Great informative video, picture quality of the recording is spot on Paul. Its a common enough car on the road still, it's very poor that these parts aren't still easy available off the shelf.

[@paulsprojects1]

thanks for the kind comment

[@SMarkP]

Crikey! Great video! I've got an R56 with a report of corrosion at the rear subframe. Ive also got a classic mini in bits with corrosion around the rear subframe. To be honest you've put me off even starting the R56 - I think I'll just scrap it and work on the classic!

[@kippamip]

Thanks for this video. I have thr pleasure of this on my 2005 cooper. Just failed its MOT and i know the car has a lot more to give. Shes 114k on the clock but still goes like a champ.

[@paulsprojects1]

just fyi, i got the replacement one from ebay, its aftermarket but seems to fit no probs, good luck with the project

[@MFSE7EN]

Very nice job! Glad you could save that car from the scrap yard :)

[@paulsprojects1]

thank you, hopefully it'll last a few more years now, thanks for the comments

[@D3Sshooter]

Well done and good istruction video - will have to do mine soon

[@PaulJames-i1q]

😱what a pain,fare play 🤪look forward to the next one👍💪🍺

[@paulsprojects1]

yeah not ideal but sorted now, onwards and upwards, thanks for the comments

[@davidking9707]

I have a 2005 MINI One with 175000 miles on it and it is still solid.

[@MyJon64]

Blimey, I thought the days of changing rear subframes finished with the old mini and 1100 / 1300 range.

[@paulsprojects1]

subframes are a really common problem on a lot of cars these days unfortunately, thanks for the comments

[@paultaylor9652]

My 10 year old mini 1984 was just a rust bucket, doesn't look like they've progressed that much.

[@andymurdoch1346]

Great video. It must be built in tradition that the subframes rot in these BMW Minis. They have virtually no protection on the chassis parts from new. I have a R56 MCS 2008 and subframes are pretty good. I've previously sprayed it underneath with the Waxoyl underseal spray but Bilt Hamber products are far superior.

[@paulsprojects1]

most people don't look under their cars and just take it to the garage- they're just interested in quick easy money so the issue gets ignored until its too late to save unfortunately

[@robh4671]

The worst part of taking things apart is you have to put them back together again after 😂😂

[@paulsprojects1]

True but its generally easier putting things back together once its all cleaned or replaced with shiny new parts

[@dcasteaux9181]

All manufacturers are playing the built-in obsolescence game: VW use steel rust-proof brake pipes and galvanised body shells - but cheap mild steel subframes which rot. Mercedes: stainless steel exhausts, alloy front subframe but cheap steel rear subframes that also rot. I guess EV manufacturers are doing the same.

[@paulsprojects1]

Cars just aren't built to last these days, the biggest irony is the wiring situation where its more complex, sensitive and connected than ever yet less robust and reliable due to having to be biodegradable etc- future wiring issues are going to be impossible to remedy without a complete new loom

[@BerwhaleTheAvenger-b5s]

Mercedes Benz are checking 10-20 year old cars and fitting new rear subframes free of charge. BMW really do need to own up and do the same.

[@paulsprojects1]

that would be really nice but unlikely unfortunately, rusty frames and chassis ( like the pickup) seem to be more and more of a problem over the last decade

[@geo752]

I think I read something about Mercedes owners taking a legal case regarding the cars having an alleged predicated lifespan and degrading to make recycling easier

[@fivedotsdave9723]

I am 99% sure this is the car that got stuck on a beach and the sea did come in to top of the wheels level.

[@paulsprojects1]

no idea, got the car from Neath area, might have been as the front subframe was in similar condition- any info?

[@markharris7662]

I think most cars now suffer with corroded subframes. They are just box sections with a layer of paint. So very little protection.

[@paulsprojects1]

yeah, its a common problem, our climate and winter road salting certainly doesn't help

[@petea7323]

My mini r50 2004 is still ok. Subframe is quite rusty but just surface rust. Now over 171k miles. Bodywork is still very good

[@paulsprojects1]

its definitely hit and miss as some are a lot worse than others, they seem fairly robust body wise

[@TheVeyron81]

no new arb bushes? theyre like a few quid each!

[@paulsprojects1]

there was no play in them, i can do them again if necessary

[@nickforder8202]

You should have put Rust inhibitor on it first that would have neutralized the rust

[@paulsprojects1]

subframe or car? the car was neutralised primed and painted, once it gets back from the MOT it'll get sprayed with Noxudol 700 to help protect it

[@johnashton700]

Frightening

[@paulsprojects1]

does make you wonder how many more out there are like this

[@AUXITOLED]

Hey,Paul. We replied to your email. But still didn't hear from you.

[@Falstaff1893]

I don't where you are but last time I saw a car that bad it had been exposed to salt air & seawater for a few years

[@paulsprojects1]

it seems to be quite common- the fact that there's an aftermarket subframe available would suggest there's a big market for them- they wouldn't bother otherwise

[@bkevbush1]

As said built in obselence :( for what is probably the biggest purchase anybody makes after a house,everyone just seem to accept that after 5 years it ll be worth next to nothing and replace !

[@paulsprojects1]

sad truth

[@TheGhost-gx5vd]

Why oh why don't they galvanise those subframes from new

[@paulsprojects1]

probable because of the cost and they make money selling parts/replacement cars

[@johnclay4811]

Why does it rust so badly? You would have thought in 60 years they would have learnt.... Clearly not!!! Galvanize possibly?

[@johnclay4811]

@Macmonkey1000 I agree I am just wondering why it is up to the owner. Subframes have been a problem since the 1950's. I would have thought by now BMW would have got a grip! As has been mentioned that should have failed the MOT! Cheers

[@adamlittle4267]

Lanoguard is what you want that will stop any future rust

[@melvynwoodman5787]

Why the surprise? Steel dissolves in salty water and we put salty water on our roads? It is in the interest of the automotive makers to make vehicles that dissolve and need to be replaced. It is not in the interest of buyers but we don’t have the power to change anything.

[@johnclay4811]

@@melvynwoodman5787 I just thought ( mistakenly!)with a safety critical item BMW would have done better!

[@paulsprojects1]

Galvanizing would be ideal but too costly i guess, cant make money if the cars last forever i guess, thanks for the comments

[@enricomercado4671]

What's with British roads??! It seems like every car there rusts like it had been under the ocean for years, with all the rust that develops everywhere in the undercarriage. Are you guys using too much salt on the roads during winter??😮

[@marcspence8838]

Yes, that's exactly what's happening...

[@becomematrix]

Uk cars…..

[@paulsprojects1]

british climate isn't kind to cars that's for sure

[@tazarcher3880]

Great video sir. My only criticism is why dint you underseal the subframe prior to fitting? also when you fitted the arb to the new subframe you dint change the bushes or clean the arb 😮. keep up the good work.

[@paulsprojects1]

thanks very much, its going to get a coat of Noxudol 700 now that its mot'd, it was purposely left clean so the mot inspector could clearly see I'm not hiding anything, the arb bushes had no play in them despite their age, I could have cleaned it I guess but this wasn't a restoration- we needed it back on the road for my wife to go to work