1964 Mini Cooper Restoration – A Family Treasure

Every classic car has a story, but some are far more personal than others.

This 1964 Mini Cooper was purchased in late 1964 by our customer Beth’s father as a 21st birthday present to himself. Over the following seven years, it became his faithful daily transport, creating countless memories along the way. Remarkably, the little Mini even completed a family holiday to Spain carrying four adults and enough luggage to fill the car to the roof – a true testament to the practicality and character of the original Mini.

When Beth’s brother was born, family life changed and, not long afterwards, Beth’s father was provided with a company car. The Mini was carefully stored in the family garage and remained there when the family moved to Dorset in 1978. There it sat, untouched, for the next 45 years. Throughout that time, he always said the Mini would one day belong to his daughter, Beth.

More than 60 years after it was first purchased, Beth and her husband, Martin, entrusted Trickett Welding with the task of restoring this much-loved family heirloom to its former glory.

Our initial inspection quickly confirmed that time had inevitably taken its toll. Although the Mini had spent decades under cover, age had led to significant corrosion and deterioration. With its remarkable family history and immense sentimental value, there was never any question of taking shortcuts. This deserved a complete, sympathetic restoration that respected both the car’s originality and its place within the family’s history.

Working closely with Martin and Beth, our aim was to preserve as much of the Mini’s originality as possible while returning it to a condition that would allow it to be driven, enjoyed and admired once again.

The following photographs document that remarkable journey, from the day the Mini arrived at our workshop to its return to the road almost half a century after it was last driven.

1. The Project Begins

The Mini arrived at Trickett Welding on a trailer in 2023, having remained off the road since 1978. Initially brought to us for an assessment, it soon became clear that years of storage had taken their toll. Although complete, the vehicle had deteriorated significantly during its long period of inactivity, and a full nut-and-bolt restoration was the only way to return it to the condition it deserved.

2. Vehicle in the Workshop - Stripping Begins

Later that year, the Mini returned to Trickett Welding and work began in earnest. Every component was carefully removed, labelled, catalogued and safely stored in preparation for the rebuild.

Retaining as much originality as possible was extremely important to the owner and, wherever practical, original parts were restored rather than replaced. This approach allowed the Mini to retain its authenticity while preserving many of the components that had been with the car throughout its life.

3. The Heart of This Mini Cooper

At the heart of this Mini Cooper is its original 997cc A-Series engine. To ensure the mechanical side of the project matched the quality of the body restoration, the engine and gearbox were removed and entrusted to a renowned Mini specialist for a complete rebuild.

This would ensure the finished car not only looked as it should, but delivered the driving experience that made the Mini Cooper such an icon.

4. Back to Bare Metal

To achieve a first-class result, the bodyshell was stripped back to bare metal. This is one of the most important stages of any quality restoration, revealing previous repairs, hidden corrosion and any damage concealed beneath decades of old paint and filler.

Starting with completely bare steel allows every repair to be carried out correctly, providing a structurally sound shell and the perfect foundation for the work that follows.

5. Protected Before Repairs Begin

Before any welding took place, the bodyshell was coated in weld-through primer. Unlike conventional primers, weld-through primer is specially formulated to allow panels to be welded together while still providing corrosion protection between overlapping sections of metal.

Once repair panels have been installed, these hidden surfaces are no longer accessible, making this an essential step in helping to prevent corrosion developing within the joints in years to come.

6. Preparing the Shell for Repair

Where necessary, the Mini’s body panels were removed to gain access to areas that had previously been impossible to reach. This allowed every section of the bodyshell to be fully assessed and repaired properly, rather than simply treating the corrosion that was immediately visible.

The work demanded countless hours of skilled fabrication, with each repair individually crafted to restore the shell to its original strength and appearance. Wherever replacement panels were required, only genuine British Motor Heritage panels were used, ensuring the correct fit, profile and authenticity throughout the rebuild.

7. Front End Repairs Taking Shape

With the repair panels trial-fitted, the front end of the Mini finally began to resemble a car once again. This is one of the most critical phases of the rebuild, as the alignment of the front panel, wings, A-panels and bonnet must all be established before any final welding takes place.

Taking the time to achieve precise alignment at this stage is essential. Correct panel positioning now ensures consistent panel gaps, accurate fitment during reassembly and, ultimately, a finished car that looks every bit as good as it performs.

Wherever possible, we replicated the original factory construction methods by using spot welds in the same locations as the car would have received when it left the production line. This helps retain the vehicle’s authenticity while ensuring the finished repair is virtually indistinguishable from the original manufacture.

8. Front End Rebuilt with Genuine Heritage Panels

Once the structural repairs had been completed, the front end was rebuilt using genuine British Motor Heritage panels wherever replacement was required.

Every panel was repeatedly trial-fitted, adjusted and, where necessary, built up by welding before being hand-finished to achieve perfect alignment. It is a time-consuming process, but one that cannot be rushed. The result is panel gaps and body lines that are arguably even better than when the Mini left the factory, reflecting the level of craftsmanship invested throughout the project.

9. Epoxy Primer – Sealing and Protecting the Metalwork

With the fabrication complete, the bodyshell and every removed body panel were coated in a high-quality epoxy primer.

Unlike conventional primers, epoxy primer creates an exceptionally durable, non-porous barrier that seals the bare steel against moisture and contaminants, preventing corrosion from developing beneath the paint system. It also provides the ideal foundation for the next stages of body preparation.

From here, the shell and panels moved into our bodyshop, where every surface was individually refined and checked. Minor imperfections were corrected, body lines sharpened and panel profiles perfected, producing the smooth, crisp finish required before the first coats of high-build primer could be applied.

10. High-Build Primer – Preparing for Paint

Following the final body preparation, the entire bodyshell was sprayed, inside and out, with high-build primer.

Where epoxy primer protects the bare metal, high-build primer serves a different purpose. It creates a uniform surface that can be block-sanded perfectly flat, removing the smallest imperfections that would otherwise be visible beneath the finished paintwork.

Once fully cured, every panel was block-sanded entirely by hand. This labour-intensive process gradually refines every surface, ensuring the body lines remain crisp, the contours flow naturally and the finished paintwork has the depth and quality expected of a concours-standard Mini.

11. Vehicle Sprayed in Its Factory Colours

After months of preparation, fabrication and bodywork, the Mini was finally ready for colour.

The bodyshell was refinished, inside and out, in its original factory colour scheme using modern paint materials and techniques. Applying colour to every visible and hidden surface not only creates a uniform finish throughout the vehicle but also provides outstanding long-term protection.

The finished shell faithfully reflects the Mini’s original factory appearance while benefiting from the durability, gloss retention and resilience offered by today’s advanced paint systems.

12. Underbody Fully Protected Following Repairs

Although rarely seen, the underside of any classic car deserves the same attention as the bodywork above it.

Once all structural repairs had been completed, every repaired section was carefully sealed before receiving a durable stonechip coating. This provides a tough, impactresistant barrier against road debris and everyday use.

After the stonechip coating had cured, the entire underside was treated with a high-quality protective wax. This penetrates seams, joints and cavities, providing an additional moisture-resistant layer that helps guard against future corrosion and protects the considerable investment made during the rebuild.

13. Reassembly Begins

With the paintwork complete, attention turned to what is undoubtedly one of the most rewarding stages of the project – bringing the Mini back to life.

Before the interior was installed, the complete cabin was upgraded and lined with Dynamat sound deadening material. Hidden beneath the carpets and trim, Dynamat significantly reduces road noise, vibration and heat transfer, making the car noticeably quieter and more refined to drive without altering its original appearance.

Reassembly then gathered pace. The front and rear subframes, steering, suspension, braking system and fuel system were all rebuilt, refurbished or replaced where necessary. The wheels were professionally refurbished before being fitted with a new set of tyres, while every mechanical component, electrical system and trim item was carefully reinstalled, adjusted and tested.

As the weeks progressed, the Mini was transformed from a freshly painted bodyshell into a complete motor car once again, with every component fitted with the same attention to detail that had been applied throughout the project.

14. The Heart of the Restoration

One of the most anticipated moments of the rebuild was the return of the freshly rebuilt 997cc A-Series engine and gearbox. Reuniting them with the restored bodyshell marked another major milestone and brought the Mini one step closer to returning to the road.

The original SU carburettors were ultrasonically cleaned and thoroughly inspected. Unfortunately, their condition proved to be beyond economical repair, so a brand-new pair of SU carburettors were fitted to ensure the engine performed as well as it looked.

To complement the beautifully detailed engine bay, we also elected, following consultation with the owner, to fit a polished aluminium rocker cover. Although not original to the vehicle, it provides a subtle sporting touch while remaining entirely in keeping with the character of the Mini. Importantly, the original rocker cover has been retained, allowing the car to be returned to its factory specification at any time should the owner wish.

15. The Finished Article

With the rebuild complete, the Mini underwent a geometry check to ensure the steering alignment was correct before entering an extensive programme of road testing. This allowed us to fine-tune the vehicle, verify every system was operating correctly and confirm it drove exactly as a properly restored Mini should.

Although vehicles of this age are exempt from MOT testing, we believe an independent inspection provides valuable reassurance for both ourselves and our customers. The Mini was therefore presented for an MOT, where it achieved a clean pass with no advisory items.

Following one final inspection, the completed Mini was handed back to its delighted owners, ready to begin the next chapter of its remarkable story.

16. A Restoration to Be Proud Of

After thousands of hours of skilled craftsmanship, the transformation was complete. From a Mini that had stood unused since 1978, the vehicle had been returned to an exceptional standard while retaining the originality and character that made it so special.

Every aspect of the project reflects the care, patience and pride invested throughout, from the structural repairs hidden beneath the paintwork to the flawless exterior finish and beautifully detailed engine bay. The result is far more than simply a restored classic Mini – it is a cherished family heirloom that can once again be driven, enjoyed and admired.

17. Back Where It Belongs

Today, the Mini is no longer sitting forgotten in a garage.

Instead, it is back where it belongs – on the road, being enjoyed by its owners and proudly displayed at a number of local classic car shows, where it continues to attract admiration from enthusiasts and members of the public alike.

For us, this project perfectly demonstrates what a sympathetic restoration is all about. It isn’t simply about repairing metal or applying paint; it’s about preserving a family’s history and ensuring a much-loved classic can continue creating memories for generations to come.