Greetings all,
Figured I should probably document some of this build so I can remember what all I've done. This project started out around 2016 when my mother asked me to find her a cool little car that was cheap too. Tall order. I looked at some of the cool little cars in the area and settled on a 2004 MCS, 6MT. It had leaks all over, a bad clutch and a few other minor issues. We purchased the car and immediately began the tear down. Here's a few pics of the first days:

 

Since this car would be going to mom in Florida, I needed to ensure that everything was in tip top shape and as reliable as possible. So we gutted the interior and cleaned everything. We pulled the door cards, added a little sound deadener and replaced the faulty door lock mechanisms. Cleaned and lubed the shift linkages, replaced the fuel filter and then stared on the body replacing broken bits. Then we pulled the engine and replaced all the seals, installed a new clutch kit, new supercharger oil, a new balancer and some misc odds and ends. The list is pretty extensive.

 

We put cleaned the wheel hubs to make sure the sensors would read correctly, replaced the rear calipers, installed new pads, sent the injectors out for a rebuild, installed a new water pump and more... (I don;t have pics of everything as it's a PITA to stop and shoot pics for every little thing)

More pics

 

After all that we got the windows tinted per mom's request (all their windows are tinted down in FL).. The paint on the scoop was worn. I tired to use some wrap to cover this but that did not go well so I simply scuffed it down shot it with some rattle can black so that I could wrap it up. I drove the car some 1000 miles to deliver the car and had zero issues. During a visit, dad asked me to help with a front end rebuild so we pulled the subframe and redid everything. New PS pump, hoses, powerflex bushings, etc. Also, new brake rotors and pads and new shocks all around.

 

After delivering this car to them, a friend asked if we could find one for her. We sourced a nice 2005 justa (manual) and fixed it up and she's still loving the car to this day!







Justa getting some attention

New wheel hubs in rear

new rotors and pads front and rear


Headliner redone

 

I enjoyed these cars so much, that I sold my BMW and purchased one for me as well- an 06 MSC 6MT Slicktop. I'll cover that one later.

In these intervening years my father has replaced the alternator, starter and door swings on the red mini. He complained that the wheels were too heavy for him (he's in his 70's) so we sourced some holey's and that helped. Nevertheless, he's never really liked the car. Recently, they purchased a new car and asked me to come get this one. The a/c had stopped working and there were several illuminated lights on the dash and the key was broken . (airbag, DSC, ABS, CEL, tire pressure). I drove the car 1000 miles home with zero issues! I was able to turn off the airbag light by buckling the passenger side seatbelt when driving.

I started to clean it up and address a few things. The CEL was caused by the coolant being too cool. I think I may have installed a cooler t-stat since it was going to be in FL heat. (no worries). The ABS ended up being a VSS that was intermittent. I replaced it and the ABS light has not returned.

I also rebuilt the steering angle sensor and had a fresh alignment but my DSC and tire pressure are still illuminated. (I just go the alignment yesterday and did not clear the codes- I'll give it a try later and see what happens.) I was receiving the "steering angle improbable code"

In the mean time we cleaned up the interior, reupholstered the arm rest and headliner, added some red stitch leather ebrake and shifter boots, modded the airbox, replaced a ripped breather tube, upgraded to a 17% pulley, new colder plugs, a new valve cover gasket, new compressor, new OEM tensioner, new belt, new tails, repainted the mirrors-rattle can, new mirror gaskets, repainted all of the trim with SEM bumper and trim paint and added some blackout to the beltline. Also, replaced the grille, but not yet sure I can deal with the poor fitment.

There's a few more things to sort, like the rest of the paint and a few of the dash lights, but it's coming along and is still great fun to drive!

faded

faded

NO rust!

worn material



Neither parent will cop to it. The dent happened by magic.

my assistant


trying our hand at polishing

replacing cracked piece

new tails


black out beltline

Added some color

 

So far, she's coming along. I have only a few more things to sort and then we need to decide if this is one we keep in the fleet (we have a bunch of other cars) or if we send her off to a good home. We were considering trying our hand at autocross, but not sure if we want to go that route or not.

If anyone has any ideas on the airbag light please let me know. The car does not have seat sensors. I was able to turn the light off and it's been off since the I rebuilt the Steering angle sensor. For some odd reason it decided to pop back on yesterday. If I connect the passenger seatbelt, it goes off.

I also still need to try and clear the DSC and tire pressure lights. I only have an AUTEL tool so I may need to find someone with INPA to help me with these final codes...

Then I am thinking about trying my hand at painting. Maybe plastidip? Those guys seem to be getting pretty good results and the product is forgiving.


Thoughts?