Saving a Troubled Trophy Winner – Another Car Saved Episode 9 “Smoke on the Minor”

We appreciate all of the incredible feedback we are receiving for these insightful weekly installments. We hope that they will in parts help you through your own projects.

Catch up with last weeks entry at the link below and then follow up with the latest entry “Smoke on the Minor”

Last weeks episode…

Saving a Troubled Trophy Winner – Another Car Saved Episode 8 “Disaster”

Saving a Troubled Trophy Winner – Part 2 of 4.

Last weeks episode finished with the discovery of large sections of aggressive rust and rot in the rear floor sections, This was through poor repair work previously made to the vehicle. It was difficult to see why the heavy gauge metal work was introduced into the floor pan, but our thoughts at the time were that it was deemed necessary to allow fitment of the aftermarket seats. These large heavy gauge plates were welded from inside the vehicle, Scarring the floor under the vehicle. These scars were then hidden by using body filler. The body filler absorbed moisture and allowed pools to build up under the ill-fitting plates on the inside of the vehicle. We tackled the floor section repairs before starting the wiring.

We held discussions with the customer to plan the route forward, with the floor mostly in solid condition it was decided that the rust would be treated, The rot cut out and the floor repaired rather than replacing the floor pans and opening up the seams to the sills. We tidied up the ill-fitting panels, Correctly seam sealed and treated the metal. Cut out the rot and made good the repair. This was a job that was kept simple and then we moved back on track with the wiring.

On to the Wiring

On the face of it, Automotive wiring, Especially on this era of vehicle is nothing to be scared of, However creating safe wiring looms and running them correctly through the vehicle is a discipline that many do not possess. Members of our engineering staff have experience of road side recovery and have seen first hand the importance of safe routing, correct connections/cables and the results from simple incorrect connections. As a result our workshop offers full design and manufacture of bespoke wiring looms to incorporate all of the electrical additions you require.

The owner of this vehicle had big plans, You’re about to see the before and after. There were so many signs that this wiring loom was incorrect that although it was a “paid service”, It was almost a privilege to know that we had saved this vehicle from being a statistic.

As we stated in the previous episode we were instructed to remove everything from the engine bay so that we could tidy up the metal work, De-clutter and repaint whilst the engine is out. Whilst untying the wiring loom we could see several areas where the wiring loom had gotten hot and fused together. Melted wires, damaged terminals and broken connection throughout.

We followed the loom back into the car where we found a more issues. The wiring loom had many areas of concern behind the dash board, An Incorrectly installed ammeter that’s wiring had obviously been hot along with other broken, melted and fused wires. These findings meant we contacted the customer to come over for a site visit, view the issues so that we could give him a couple of options moving forward. We put the idea to the customer of having a custom made wiring loom. We would design it to reflect that of a modern vehicle with state of the art, modular fuse and relay box. We would design it to incorporate all systems including the new ones being wired in over the winter. Each system to be independently fused to remove the risk of melted wires in future.

The client was especially keen on this as an added safety feature due to his friend and fellow club member who had a new loom fitted before a recent trip over seas and the vehicle caught on fire due to lack of wire-through grommets and those new wires chaffing through on the bare metal. We had noticed the lack of wire-through grommets when that particular vehicle came into us for some wheel spacers to be fitted. It was flagged as dangerous by our staff but sadly not acted on, Thankfully no one was hurt.

Our WORKS Morris Minor Traveller. Equipped with all of the state of the art additions created.

The client was shown the loom we had created on our works Morris Minor Traveller (pictured) and wondered if we could locate his main fuse box inside the vehicle to keep the engine bay tidy. We accommodated his wishes and designed the system so that access to the fuse box would be from the front parcel shelf under the dash with the loom located up behind the dash. A very nice system.

There were several systems that would feature in the new loom, These include:

  • ASD Remote Central Locking, This operates on both front doors and the rear doors. The rear door system is built to suit the vehicle.
  • Alarm and Immobiliser
  • 4-Way Hazard Warning.
  • Brake Fluid Warning.
  • Intermittent Wiper System.
  • Thatcham Tracker System.

These systems would be wired into the loom running through their own independent circuits, There is space in the new fuse box for each system to run independently.

This concludes the wiring stage of this project, As you can see we are really starting to break the back of this project and turn it into the car it always could have been.

With 2 episodes left following this one you will see the strip down of the engine, Why was it performing so badly? What was the issue and could it have been an outside source that caused any faults or damage?

Lastly in the final week you can see how the late nights and early starts combine to start putting this tired, troubled car onto the mantel. The last episode is a bumper edition (no pun intended) as we cover;

  • The complete strip down of the body
  • Bodywork, Prep and Respray
  • The Final rebuild
  • Everything else we find along the way.

You will be able to read and see how we got on with this build. How could a gearbox cross-member damage the chassis? Did our staff really refuse to refit the tow bar, Was it really that unsafe? See how we transform this car into a headturner! Check back next week to see how we start putting this back together!

FOR ALL YOU MORRIS MINOR OWNERS We have huge offers on all Morris Minor Parts and Accessories for the duration of this 4 part instalment of “Another Car Saved” Click here



Four Module Housing

Four Module Housing Cover

Maxi-Blade Fuse Module

Micro Relay Module

Mini-Blade Fuse & Maxi Relay Module

Mini-Blade Fuse Module

Standard Relay Module


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