(#2), Custom parts & mods

  1. 22 sets of 3.6 "Frana Cars" final-drive gears received for one-time group buy.
  2. Frana 3.6 Ring gear (on left), is .75 pound lighter than stock 4.26 Integra LS gear.
  3. Frana 3.6 (on left), is hollow drilled & 1 pound lighter; teeth are thicker and have less helix (twist) than stock.  Makes some noise, but not as bad...
  4. Frana gear (bottom), has less helix, bigger teeth.
  5. dash installed with 91 Honda CRX instrument cluster, LED panel switches.
  6. Glove box doors are made from European Plane wood, (Lace Wood).
  7. Left glove-box door holds fuse boxes.
  8. Carbon/Kevlar door prototype weighs 3.5 pounds....(A stock glass window weighs 8.5 pounds!)  Expecting a weight savings of 76+ pounds with these new...
  9. Hope I never get broad-sided; this door is like a big potatoe chip.
  10. 2 stock steering column housings and a stock solid steel shaft, shown with 4130 (chrome-molly) tubing.  Housings will be cut and spliced together for...
  11. Cut the splined end off the stock Mini shaft and turned it down to fit snug inside the 4130 tubing
  12. Stock splined top section to be welded into 4130 tubing end, and stock Mini lower end, with pinch clamp is inserted into the other end of the tubing...
  13. Close-up of turned down splined end to fit in tubing.  Old stock cut-off Mini shaft is on right
  14. Press in the pinch-coupler end, then weld around and plug-weld.
  15. Plug welded & end welded coupler into the tubing & make a delrin bushing to replace the stock wobbly felt bush.
  16. Steering wheel spline is plug and end welded into tubing. with new stock nylon upper bushing in place.
  17. Finished steering shaft.  A middle bushing was also added to help prevent the shaft from "bowing" internally.
  18. A middle bushing and stop ring was added, to keep the new shaft from flexing inside the column tube.
  19. Another 3 pounds of ugly fat was removed. these things are heavy!
  20. That's better, about half an ounce, and no keys to fumble with.  Hidden toggle switch will be used for ignition.
  21. Under side of extension bracket. This is for filling the gap between the dash and the end of the Mini plastic column cover, plus it helps stiffen up...
  22. New bracket replaces old.  You can see the dropped-collumn position, necessary to  partly compensate for the 4" column extension;  The wheel ends up...
  23. Aliminum pinch clamp, anchors the longer steering column tube.
  24. left side of Finish mounted column with extension bracket.
  25. Finish mounted column with extension bracket, right side view. Wiper stalk removed, along with harness, wiper motor/mechanism, and wiper blades, for...
  26. All stainless adjustable muffler installed, with internal bypass valve, operated by a push/pull rod from the drivers seat.  This came out quieter...
  27. A simple way to make your own stainless muffler tube:  Clamp the thin .022" thick sheet between a piece of pipe and  something straight and stiff;...
  28. Since it is stainless, you can use very thin material without worrying about rusting through; thin stainless (22-26 gauge) is very easy to bend.
  29. Once the sheet metal has been formed into a tube, it is clamped together and seam welded.  It doesn't have to be a perfect weld, since it will be...
  30. the throttle blade must be machined in an oval shape, so a mandrill was made to mount the disc at an angle, so it could be turned on a lathe,...
  31. The guts of the muffler assembled.  You can see the path that the exhaust gas must take when the center valve is shut. The valve blade is still on...
  32. Valve is test fit on the 5/16" stainless shaft.
  33. Valve in shut position.  It must be machined in an elliptical shape so that it seals at an angle, although a perfect seal is really not necessary. ...
  34. The valve was installed onto the shaft with two screws, which must be staked in place, requiring that the pipe be cut off near the middle, for access...
  35. Valve in place and pipe halves welded back together.  There really are such things as "muffler bearings"!
  36. The 24 gauge stainless shell (very thin/ light) and fairly easy to form around pieces of pipe, taking some patience.  (first time for me)
  37. Stainless steel packing material in place before welding on the end cover.
  38. valve shown in the open or straight-through position.
  39. Valve shown in closed position, which forces the gas out through the perforations, through the dense packing, through the perforations into the two...
  40. Clamped shell for welding the seam and end caps. Note valve shaft protruding through the top skin. A lever will be attached and operated by a 1/8"...
  41. finished muffler weighs 4 pounds; the stock galvanized Mini box weighs 11 pounds if I recall correctly.  You can see where I cut it open, just to...
  42. The Honda throttle ratio winds up being too quick when used with the stock Mini gas pedal lever ratio;  This makes pedal modulation very touchy, and...
  43. Only idle to part throttle is changed;  once the throttle reaches about 1/3 open, the extension piece is no longer in contact with the cable, so the...
  44. Here, the throttle linkage plate is re-installed on the throttle shaft and the cable hooked back up.
  45. Before I did this mod, my car was  totally un-drivable in slow traffic;  a little gas pedal movement and the car would lurch forward, causing my leg...
  46. Removable slam panel modification facilitates engine access and header removal.  Pop rivets are used on outer side of the joint(painted yellow), and...
  47. positioning the brackets temporarily, using "Clekos", prior to riviting permanently in place
  48. Fabricated brackets for installing the removable slam-panel.  6-32 nuts are welded on the back side.
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