Hi does anyone know what early Australian Minis had foam filled sills and roughly when they ceased the practice here? I have had a 65 Deluxe and a 66 S that didn't have foam filled sills (but did have very rusty sills thankyou very much). In contrast, my 64 850 current project, and earlier cars that I have had seem to have stayed pretty rust-free.

Matt

Good question!

A friend had a new 997 Cooper that he had spilled a pint of milk in one of the rear pockets and I vaguely remember him saying he might have to sell the car because the foam in the sills was holding the smell...

I also vaguely remember seeing foam through the rear pockets of a 66 Deluxe but can't be sure

BTW Early cars had thicker steel...

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"Show me the Mini!"

I have removed rust from sills on 62 cooper 64 cooper and a 67 S never see any foam in them

HI TartanRed
I don't think they were ever foam filled from the factory,BUT back in the 60/70s in rally cars and series production cars they foam filled the sills to try and get some stiffness into the chassis for better handling.
Graham Russell

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"It's better to be not informed than ill-informed"

I had an early 850 as my first car. 1961 with the tube frame UK seats.
I recall back then there was criticism of their foam filled sills. As they gave off toxic gases when cut or welded.
Never repaired this car body so I'm not sure if it had foam in them.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I bought home a cut up early car before they changed the sill design dont remember it having foam either

For real GR (I can't see whether you have a grin or not...this could be a possible leg puller!)

[PS I could see someone adding sill ballast to lower the CofG if you had plenty of power to compensate]

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"Show me the Mini!"

It was once common practice for panel beaters/body repairers to use the expanding foam in sills etc. as part of the repairs they were making. Seem to remember this happening mostly in the 80's. Haven't seen foam in any of the Minis I have repaired including 62-63 Coopers and a 1960/61 CKD 850.

the use of foam inside the sills was stopped late 59 early 1960 when the floor and sill lapping design was revised.

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....you just lost him his insurance bonus!

997

It was later than early '60. My early '61 Traveller has foam filled sills. It comes right up the front door frame to at least where the wiring loom enters from behind the dash.

I don't know if the 850s being built in Australia at the same time had them.

cheers
Tim

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1951 Morris Commercial J Type Van
1955 BSA C11G
1961 Morris Mini Traveller
1969 Triumph TR6R
1977 Leyland Moke Californian

According to AKD1181D (UK issue):
Introduced on saloon 31955, van 10956, traveller 2203
Discontinued at body L69999 (except no. 70601 to 70630)

UK build number 70600 is around Aussie car 4000, approx 8/61 to 9/61 ?

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I reckon it would be fairly well known among Mini enthusiasts by now if Australian assembled cars had foam injected. I'm not aware of ever seeing it in a car.

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ex-NSW Police 1970 MK II Cooper S
VMCI #43

Thanks for all the replies. I was under the impression that at least early 850s here were foam filled but I had no evidence. That's why this forum is great - a wealth of knowledge! I will keep asking random questions and see what is down the next rabbit hole!
Cheers

PS: I guess the rust treatment must have simply been better on the early cars than the later ones...

What was the purpose of the foam?

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67 Deluxe
Dry suspension
1293cc, 11:1 comp, RE 282 camshaft, 45 Weber, extractors etc
4 synchro close ratio gbox
Cooper S brakes, no booster
Stealth box, as Doc says "goes harder and idles!"
RH tank cos I needed it crossing the Nullarbor etc..

I'll go out on a limb and say sound deadening and filling a void that could normally be subject to condensation etc and therefore corrosion

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"Show me the Mini!"