How Do You Improve The Original Pocket Rocket?

When Chris took a call from one of our previous clients on the subject of improving his “station car”, he couldn’t have imagined how exciting the project would become!

We are used to working on small performance icons but this would give us the honour of working on hot hatch “ground zero”, even though it isn’t technically a hatchback . Punchy front mounted transverse power unit, wheel at each corner stance, nippy handling and maximised space in a small package, sounds familiar to us here given our connection to the Peugeot 205 which feels like a direct descendant of this Mini.

Once the brief was set we then collected a rather careworn but still beautiful 1968 Mini Cooper S from our client and trailered it back to our Marton workshops for evaluation. The classic Tartan red with black roof was going to remain, as would a handful of period accessories - more on that later. This car was going to be restored to a high standard but retain its original look...

During evaluation some of the younger members of the team were genuinely surprised at how much space there was in this tiny car, it easily accomodates drivers well over six feet tall. Hugely innovative at launch in 1959, the Mini showcased previously unseen packaging genius from the days when the British motor industry led the way. Only later was it noticed that the platform gave great advantages in handling and along with John Cooper Garages and the BMC Competitions Department many high performance variants were developed and and proven in competition. With saloon car racing success and a period of domination in international rallying the story has now passed into motoring folklore.

The current custodian of this car has kept it in regular use for well over a decade, and has a complete history of the car that traces its story, along with the few modifications back to the beginning. The brief was relatively simple, restore the body which was pretty good for a 60s Mini but it was hiding significant rust and some poor body repair from years gone by, rebuild the engine and gearbox, nothing radical or highly strung as this will remain a regularly driven road car. Add a few modern conveniences to aid comfort and reliability whilst retaining all of the characteristics that make a Cooper S so captivating and fun. This was never intended to be a showpiece, just a really good useable car which would remain in long term family ownership. As is normal for a Tolman build, all of the modifications would be subtle (preferably invisible), and completely reversible.

The strip down process can often reveal historic secrets and apart from some pretty makeshift repairs, one of the most amusing discoveries made during the “automotive archaeology” phase was the Weber box that had been let into the bulkhead at some stage to accomodate a different carb set up. As can be seen in the pictures, a hole had been roughly cut into the bulkhead and then filled with a piece fabricated from an old tin can had been riveted in place. This was once considered acceptable, needless to say, the offending piece has been kept for posterity!

Once the painstaking restoration of the body shell was complete, the doors had to be heavily modified to acheive a good panel fit which goes to show how our expectations have changed! A very high quality paint job was then applied before the build could begin. The suspension was re fitted as a fully adjustable dry cone set up allowing fine tuning of all angles and ride height. The A-series engine, along with the gearbox completely rebuilt, metal components re plated or painted as required, rubber components replaced, perfect stainless pipes from ATEC ensured a good fit and reliable pedal feel. A new wiring loom was fitted to accomodate the updated vehicle electronics, mainly the new engine management system which allowed optimisation of fueling, improved cold starting and far better driveability, it’s a transformative change.

Sound deadening was added, as well as vastly enhanced corrosion protection. Seats were retrimmed in leather and creature comforts such as bluetooth and front and rear heated screens fitted. A deliberate choice was made to retain and reuse as much of the original trim and brightwork as possibe in order to maintain some sense of history and some of the beautiful patina of the car.

The finished car looks fantastic on its 10” Cosmic alloys with period correct Dunlop Aquajets, the Dunlop hubcaps remain with their patina in place. The Webasto roof which was fitted sometime early in the cars lif is now watertight and fully functioning. New carpets and refreshed dash with a period style tachometer together with the existing (but tidied) steering wheel give the interior a lift. Adding to the modernity are inertia reel seatbelts, a bluetooth radio and enhanced lighting.

The new (very small) battery and the management system are now hidden in the rear of the car, with the collector and fuel pump relocated to the battery box in the boot, which itself is neatly hidden below a carpeted boot floor between the twin tanks.

There’s just too much detail to list here but this was a real labour of love and it shows in the end result.

A lot of time went in to optimising the set up of the fuel injection system for maximum driveability and the suspension for the best in British B road handling. After a good (and fun!) shake down and final spanner checks the car was treated to some more underbody protection ready for the winter and a thorough detail with our ultimate ceramic coating before being handed back to a very happy customer who is now enjoying Englands back roads in his very own ulitmate British Pocket Rocket.

It has been a privilege to work onthis little icon, a big thank you to our client.

If you have a project in mind please contact us to discuss...