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AeroCatch Case Study Yamaha R1 Powered Mini

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The “R1 Manx” is a home built project car based on a 1991 Classic Mini Cooper. The 'R1 Manx' name originates from the power unit, a 'Yamaha R1' motorbike engine, and from the nationality of the build team, Benjamin Duke and James Karran, who are from the Isle of Man. I (Benjamin) have been the proud of owner of my mini since the age of 16 and it was my first car.

After a few years of very enjoyable motoring, the shell began to show the classic signs of mini rust syndrome in the A panels and boot floor particularly. With a forthcoming gap year of travelling and generally living the dream looming, I decided to take the mini off the road and strip her to a bare shell which could be dry stored in the garage. This was done with a view to restoring the mini to her former factory spec glory on my return. However, i've always had an interest in motorcycles given that the famous TT races are on my doorstep, and also for the fact that my Grandfather Geoff raced bikes for a living in the 1950's. This encouraged me to look at transforming my mini into a motorbike engined beast. And so, following a beer fuelled discussion with my friend James about the idea, he remarked that if I went ahead and bought an R1 engine then he would help me install it into my mini. This swung the vote for me and shortly after I purchased a 2003 Yamaha R1 engine which would eventually be the 150bhp beating heart of my special mini.

With the engine now in the bag and the decision to run the mini as a FWD car to retain some it's original driving character, we got down to finding a suitable home for the motor and all other necessary components into the engine bay. This proved to be a trickier job than we'd initially envisaged, as the engine, radiator, exhaust and drivetrain, soon congest the engine bay so this was a time consuming task.

Regarding the drivetrain, we decided to retain the factory output sprocket with the intention of mating it with an open differential (QDF14K Quaife ATB LSD) and sprocket/chain setup. This would be a crucial metaphorical cog in the 'R1 Manx' machine. We created our own oil/grease can for the diff, bearing blocks, sprocket adaptor, diff cradle and chain tensioner. The driveshafts were then cut-and-shut to custom lengths and these would engage with the standard mini hubs. Once we'd found an ideal engine position with all other components accounted for, an engine frame was constructed from 25mm tubular steel. The intention was always to try and retain as much of the original mini subframe as possible and we only had to remove and re-locate the front cross member which was great. We also retained the original style mini hubs, brakes, steering and suspension.

Over the following months/years we spent time refining the mechanical side of things with a test run at a local trackday circuit being an absolute success. We turned up with no front end (flip front) on the car and no windows and the pit lane marshals gave us the classic, 'that thing won't complete a lap before it breaks down' look, and off we went into the abyss. I must admit there were some reservations as to how far we might get, but after a few clean and steady bedding in laps, I decided to pull the pin and see what she could do. Needless to say, the mini was a proper weapon and she certainly had the marshals gorging on humble pie as we screamed past at 12000 rpm!

With the mechanical side of things now pretty much covered, it was time to look at the bodywork and paint job. I purchased a clubman style flip front (the round nose had to go after we admitted defeat trying to fit the motor inside it) and decided to combine dzus fasteners with Aerocatch latches for mounting it to the shell. I could have gone for dzus fasteners all round but I chose Aerocatch because they are a snug and secure fit with the option to have a locking type catch. And removing the front end would be easier with having something sturdy to grip on to when opening the latches on the mini A panels. Furthermore, I'd seen lot's of mini builds with dzus fastened flip fronts, but none with Aerocatch, so in the spirit of being different it was the right choice to make. Once we were happy with the Aerocatch fitment and the flip front position, it was time for the paint job.

For the paint livery, I also wanted to do something different and seeing that I have an interest in motorcycles and also have a passion for anything totally retro, I decided to represent this in the paint scheme. The final mini design is based on the 1978 'Kenny Roberts' Yamaha YZR-500 bike with the 'speed blocks' down the side. In order to successfully celebrate this epic design on the mini, it was then up to my friend and paint guru David Anderson to wave his magic wand. He did a superb job and really threw himself into the project with plenty of his own passion for custom cars and motorcycles.

The 'R1 Manx' project has taken 3 years of dreaming, planning, brewing cups of tea and putting my heart and soul into my own special mini. The build cost came to about £12000 in the end, including the paint job. This project was only possible with the help of my friends who all offered there own dose of knowledge and expertise. I think that's ultimately what makes a project special, when lot's of people around you pull together to share ideas and different ways of building certain components on the car. I can't thank them enough.