Welcome to the latest instalment of our DIY Mini Restoration series! In this guide, we revisit the Bogus 2 Mini build with a focus on fitting the clutch and flywheel. This crucial step ensures your Mini performs at its best. For any technical advice or assistance, feel free to contact the Mini Sport team. Let's get started!
Engine and Gearbox Assembly Guide: Bogus 2
Joining Together: Engine and Gearbox Assembly
Bolts and Lock Tabs
Some earlier Mini engines used lock tabs for bolts within the clutch housing. Although Rover later specified 5/16-inch flange-headed bolts, the lock tabs are still worth using if you can find them. They help secure the assembly and are a nod to classic Mini engineering.
Connecting Engine to Gearbox
For connecting the engine to the gearbox casing, Mini Sport employs cap-head bolts for most of the assembly. However, in one tricky spot just above the diff housing where Allen key access is limited, a standard hex bolt is used. This combination ensures a secure fit while navigating tight spaces. Shop all classic Mini Nuts, Bolts & Washers >
Bolt-on Bits.. Ancillaries
Water Pump Options
We’ve chosen a high-capacity water pump with a cast iron impeller. This pump offers improved capacity and reduced cavitation compared to stamped steel-bladed pumps. While this pump fits most blocks, check clearances if you’re using a skimmed block. Electric water pumps are also available but be cautious of excessive flow rates and ensure proper speed control with aftermarket ECUs. We have a selection of water pumps available to purchase >
Timing Chain Cover and Breather Setup
We’re using a late standard timing chain cover with a ‘squashed’ breather and an 11-blade plastic fan. Earlier casings lack this breather, and some have timing marks set at awkward angles. Standard breathers are typically connected to the air filter housing. For our setup, we might route these to a catch tank to handle blow-by gases more efficiently. For the full range of cooling & heating parts click here >
Oil Pressure and Temperature Sensors
We’ve installed a DigiDash2 oil pressure sensor with dual spade-ends for both pressure level indication and low-pressure warnings. A Mini Sport custom distributor-blanking plate replaces the distributor, as we’re using a KAD timing wheel. For oil temperature, we’re testing a new Mini Sport setup with a sensor in a modified sump bolt, allowing direct oil flow to the sensor. Discover our range of Engine components >
Final Assembly
With the engine and ancillaries set up, the power plant is ready for its next stage. From Mini Sport’s engine shop to the assembly area, Bogus 2’s 7-port engine is sure to turn heads at Mini shows! Shop Our range of built Mini Engines >
Need Technical Help?
Our team at Mini Sport is here to help with any questions or technical challenges you may face during your restoration project.
Explore Our Range of Products
Check out our gearbox components and ancillary parts to find everything you need for your build. Stay tuned for more detailed guides in our DIY Mini Restoration series!
Want to read Keeping Your Mini Alive 6th Edition Magazine? Download the PDF here
Don't miss out on the rest of the Bogus 2 Series!
This blog series is your go to for a guide to taking your Mini from a bare shell to a road-worthy classic. Check out the rest of the series for tips and advice from our Mini Experts for every stage of your Mini restoration!
This guide is meant to provide general guidance and a step-by-step approach to build your Mini's Engine. It is always recommended to contact a trusted professional if you are unsure about any part of the process or lack the necessary tools and experience.