I'm currently working on a mid 80s Mayfair, It was dolled up back in 2000 and shipped over. The buyer and current owner had it converted to LHD, wood dash with tach and 5.5 alloy wheels. His two sons took turns, one drove it to high school, then the other son drove it though high school then to college as well. Once done with school the car has lingered in my shop for years. Due to health issues in the family we put the car up for sale last year. Being a nice little 998 able to run 70 mph all day and give great MPG we set a price. No offers met our price. One buyer ask for a complete survey of the car and if it met expectations he would meet our price. The car is very sound boot and floors, sills and in general. Suspension and brakes were fine but springs needed replacing. Normal suspension rubber issues. The compression test showed #4 cyl. at 70 psi. Needless to say this killed the deal. The owners not wishing to sell a lemon have had me go though the survey list and correct issues. Like any can of worms we were in for a ride.
Power unit was pulled, #4 cyl. showed .008 wear the balance were closer to .003. Having a collection of 998s I stripped four engines and used the best A+ block with .0015 wear which allowed honing and fitting new rings. I picked the best std./ std. crank and the best set of rods and pistons. New cam and lifters, oil pump, cam bearings, rod and main bearings. Iwis chain new timing gears and tensioner. Block was honed, cleaned, cam bearings, brass freeze plugs and surfaced. Cyl. head got the full lead free treatment. New guides, hard exhaust seats and all new valves, springs, caps and keepers the last generation of 998 lead free multi groove valves, matching bits, rocker shaft, and seals of course.
The tranny a DAM 5626 must have been under a 1275 at some point in it's life. As well as it drove and (I did take it out once in awhile) The tranny was a mess. Like so many 5626 I do, the double ball bearing ( third motion shaft bearing ) had broken ball spacers. Parts list goes something like this. All new bearings, main shaft, lay shaft, synchros, shift forks, detent springs, diff. cage, spider gears and diff. pin. Diff. side covers rebushed and align honed to size. A center oil pick up tube and the 3.2 CWP were installed with new gaskets and seals. I tried to buy a good DAM 5626 core but the last three I have picked up were to bad to use the case and the parts were worse. The tranny repair did mess up the budget. Flywheel was surfaced and new pressure plate and clutch disc, TO bearing, plunger, arm, push rod, slave, hose, hard pipe and master. Rod change shifter was rebuilt with new bushings and rod eye.
The front sub frame had a broken lower front dog bone mount. The bulkhead dog bone mount was about to fall off. A freshly powder coated front sub frame was sourced and built up. New MSC rubber springs, HI Los, on car adjustable lower arms and tie rods. Upper arms rebuild, hubs cleaned glass beaded and new Timken bearings, ball joints. CVs and pots were stripped cleaned greased and booted. Axles were cleaned glass beaded checked for straight, painted and assembled. The 8.4 disc were replaced with new and the calipers were kitted and new SS pistons installed. Steering rack was rebuilt with new non drivers side bush replaced and boots and ends replaced. Dust shields, stainless hoses and hard pipe installed.
The rear sub frame did not come out, but rear swing arms had been done since coming over and were tight. Backing plates were removed cleaned, glass beaded and painted. New adjusters, wheel cyls., brake shoes, springs and spaced drums. Rear ball bearings and the rear should be fine. The brake master has been replaced and we bled the brakes yesterday. I plan to put on ground today and align suspension.
The exhaust and intake manifold, carb. and exhaust system all received attention and look nearly factory fresh. The engine compartment was cleaned sanded and painted. The bulk head dog bone issue was addressed.
I have installed a new ignition switch and have a couple of electrical issued to deal with. New head light switch, choke cable, hoses and I'm ready to see if it gets better MPG on 4 cyls rather than three. I also wonder if it will be faster.
Removing the slip covers reveal some tired seats. The plan is to order a new interior and have some scuttle minor rust issues taken care of. If we go that route it's for sure the car will be a nearly needs nothing car. I do want to get new 165/12s also. I'm thinking we can buy tires and enjoy the car as is.
If someone is looking for a nice mini with a good idea of current condition get in touch with me. We know we are over budget but we can answer all questions honestly.
My body and paint guy passed away last November. We were ready to address the body issues but all that has changed. If a very sound shell and mechanical completely fresh car is something you would be interested in get in touch.
PS if speed is your thing I have Metro power unit cores and we can go crazy. Steve (CTR)