Chassis jig with a cut down original Mini front s/frame. Just showing the drivers side. We have removed 330mm from the width.

Front drivers side suspension mounted on chassis jig

Capturing the original Mini bodyshell side view on a 3d scan in order to model it in Fusion and reduce it in size to 80% or 4/5ths scale.

3d Scan of original Mini Bodyshell

Another scan being captured, this time of one leg of the rear suspension after being cut out of a full size Mini subframe.

3d scan of rear subframe section

Mock up of passenger side rear subframe being mounted on chassis jig after being reduced in width.

Part of rear subframe mounted on Chassis Jig

Middle chassis section beginning to be fabricated. This shows the complicated angles at the front toe board & wheel arch intersection.

Middle chassis section before welding

Middle chassis section after welding up side members to cross member at front toe board area.

Middle chassis section welded

Front toe board (3mm thick steel) in place with wheel clearance cut out.

Front toe board

Front tower mounts being mocked up.

Front tower mounts

Design drawing for additional legs to front subframe for mounting points to toe board.

Design drawing for front subframe

Rear subframe bolted in position against the fabricated mounting.

Rear subframe mount

Rear chassis legs and crossmembers to support rear mounts of rear subframe and shock absorber upper mounting points.

Rear chassis legs

Chassis mockup complete - this is the 1st time it's been rolling on it's own wheels (8 inch ones at that). Judge the size by the door behind

Rolling chassis mockup completed

Paper template being checked for floorpan top hat channels. This has been produced by measuring the original Mini floorpan & scaling it down

Template for floorpan top hat channels

Part of the learning process: 2 out of 3 sections made & laid onto original Mini bodyshell to check accuracy. 3rd piece still being shaped.

Part complete Mini front wing - In aluminium

Full size front wing in Aluminium. All 3 pieces tig welded together, before being planished to a smooth surface. Again, a learning piece.

Welded-up front wing - In aluminium

Full size, being shaped out of 1.6mm thick aluminium in one piece. This was a further test panel to help learn the process of wheeling.

Mini rear quarter panel - In aluminium

Here we wrapped the completed panel in a carbon fibre vinyl wrap to check what the surface finish looked like.

Mini rear quarter panel - In aluminium, with carbon fibre vinyl wrap