From Zero-to-Hero: Mini Cooper S Restoration

Back in March 2016, we were tasked with a restoration on quite a special Mini indeed... Alex Munday's 1996 John Cooper Works Mini Cooper S, an original from the John Cooper Garages, production number 79, and allegedly previously owned by British rally driver, Alistair McRae! When following his life-long love of Mini's Alex purchased this Cooper for family adventures, it came as a devastating blow when he brought it to us for a service and we regrettably had to tell Alex that the shell was in fact rotten, facing the agonising decision of loosing this Mini completely, or going down the costly route of restoring this beloved car back to it's former glory, he eventually chose the latter, you can find out exactly what special treatment Alex's Mini went through below:

Once Bas had re-assembled the Mini, having completed the necessary repairs, it was time to seal the Mini - to keep it water tight and prevent rust, before moving on to etch-priming and priming.

Once primed, Bas was ready to apply the colour, Flame Red, to Alex's Mini in our spray centre. Starting with the underneath, before moving to the interior of the shell, the exterior, the roof (in Diamond White), before finally painting the doors, bonnet and boot.

 

       

 

At this point the Mini was then handed over to our Workshop technician Michael, who following on from wax oiling all the cavities, set to work transforming this coloured shell back in to something resembling a Mini once again.

Beginning with fitting the subframes and a wiring loom before moving on to fitting the, pedals, dash, handbrake and perhaps the most important edition to date, the engine and gearbox!

The next step whilst on the ramps in our fitting bay was to begin fitting the interior trimmings, Michael set to work with the aid of Basil and had soon fit the headlining, the steering lock, the steering column switch, the dash and the carpets.

The Mini was starting to shape together nicely and was looking very tidy indeed, the back seats, interior panels and centre console were then fit before the doors were fixed on.

Once Michael had completed all the mechanical work, this Cooper was then back in our body shop with Basil to be decalled and have the remaining chrome trim, such as the grille, fit.

Finally the Mini was up and running again, and it was time to be put through a full diagnostic check and finished off with a tuning on our rolling road.