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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #21 ·
Managed to get a look at the quality exhaust while I was getting the tracking done earlier (which they couldn’t do as the track rod ends were seized) and its sure a quality piece of kit, something Bentley would be proud of!

quite simply it a piece of mild steel pipe welded to what looks likepart of the original front end of the standard exhaust running straight through to the rear, no res box and I wasn’t joking when I said it wa as Halfords tail pipe end!






thing is it works, isn’t at all noisy and looks ok from the back but at some point I’ll most likely get a custom made exhaust on it with a resonating box as I can’t imagine a straight through piece of scaffolding isn’t helping the turbo back pressure, I could look at a Cooper SD exhaust but they are for 2l cars and the manifold may be further forward or back on the 1.6 car so it may not fit, similarly the Cooper diesel exhaust will fit the manifold but it’s a side exit type so won’t fit the bumper, another option is an amalgamation of the two types

It’s also had its heat shield removed so I’ll look at putting that back on if I can find the bits cheap enough

most importantly I’ve got an aero grille and OEM mini spotlights for it, got to have it looking good if nothing else
 

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also looks like the cat/dpf has been smashed out if that pic detail is what I think it is? Plate welded over the housing, will fail an MOT (evidence of interference)
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #23 ·
Yeah, noticed that too! It’s MOTD until December so plenty of time to source a replacement
 

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2.0d motor is totally different, turbo/mani/DPF at the back, but the link pipe could be adapted, only a short pipe so not high cost
WP_20201013_003.jpg
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #25 ·
Ended up getting a used standard Cooper D exhaust for the car, will have to change the bumper though for a side exit type, I also managed to get the cat for it too off the same seller so it will have a standard exhaust set up once I get it on

it’s what in the mini world is known as “doing a pipsyp” I take mods off the car!

the chip tuner has arrived, ready to be sent off to be reprogrammed for my car as well as the beltline de chrome and Cooper S spoiler so they will be going on to keep the balance of the universe in tow, for every mod removed one must be refitted!
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #26 ·
Cooper S spoiler fitted, so much easier to swap than the R53!
103604


Beltline done
103602


and a phone holder
103603
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #28 ·
I’ve had to dump that lot in the mess room at work as it was all in a hire car, going to collect it tomorrow, hopefully get the car on some ramps on Sunday as it’s my day off and see if I can get the exhaust off, if I can then I’ll also swap the bumper over

as for the other boxes in the boot this is what I’ve got to fit

rear lights
103623


front lights
103624


LED driving lights/fog lights
103626


LED indicators
103627


sprint booster
103628


JCW strut brace
103629


103630


and then when I got home a parcel was here from eBay, black door handle covers
103631


and off Amazon a Bluetooth adapter which plugs into the aux port so I can stream from the iPhone to the stereo, a bargain at £6 that one!
103632
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #29 ·
Oh and the TDI Tuning box, ready to be sent off for reblowing for my car, it will take it from 108 to 143bhp and increase ‘the torques’ from 177 to 223ft/lb

103633
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #30 ·
Right here we go.......

today was the day to try and get all the bits on the car, started about 8:30 and got a good days work done!

here is the car as it looked the start of the day


Started with the simple jobs, front lights first


Then the side repeaters


JCW strut brace


Then it was off with the bumper to see if I could do anything with the exhaust

as you can see it’s top notch!


Then once I was sure I could do something with it i ramped up the front of the car to get to the manifold bolt


I then wd40d the rubber holders for lubrication and yanked the exhaust from the back and it slid off the hangers very easily, in all fairness I could have talked it down it was that loose!




It was then on with the new exhaust




And Cooper bumper


That lot only took me about an hour and a half, was expecting it to take longer, next up, back to a simple job, rear lights


I’m going to retain the chrome around the headlights and taillights as well as the grill (which will be going black)


Then it was the sprint boost button, plugs into the accelerator pedal and has the button on the dash, similar experience to the ones I had in the Cooper and convertible


Then the one job I was going to put off as I didn’t fancy taking the bumper off but I thought, what the hell ive got plenty of time left


Daylight running lights, you may notice the chrome ring is missing, I’ve taken it off to plasticote it black


They are wired together and an extra loom runs to the battery, when the lights of off you get bright running lights but when the lights come on they dim down




And there we (almost) have it, still waiting to fit the spotlight rings, I’ve also got a black grille on order, I’ve been looking for some brackets for the spotlights and I discovered mini do a kit with the brackets, plastic grille back and gloss black clip on slats so I’m going to order one of those as it’s cheaper than I trying to get brackets and an aftermarket black grille on eBay!


On the rear I’ve got a black boot handle cover on the way too


By the end of the week I should have the tuning chip back too with any luck

Just so the R53 didn’t feel left out I took it out for a drive while the R56 was on the ramps!
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #33 ·
Took to out for a proper spin this morning taking my lad to work, it certainly goes well for a standard car so it should be pretty good once the chip is fitted, the sprint booster make a bit of difference too as it is now

it’s a different drive to the S as it’s not a plant your foot down and watch it go kind of car but it pulls really well just driving It sensibly and with no aggression

I think I need to adjust the headlights a bit as they seems to be pointing a bit low when I came back from work in it last night, and one of the high beam bulbs has blown too so I need to take the light out to replace that.

ordered the black grille last night so hopefully that will arrive tomorrow so I can get that fitted along with the spotlights, got to rub down the blacked off bumper spotlight rings as there are a few runs on them, going to do that in a bit
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #34 ·
Black fog light rings back in place
103647


I think the headlights need adjusting in the brackets before I adjust the screws on them as they are a bit off centre in regard the chrome ring
103648


this one is pointing outwards
103649
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #35 ·
Now this i do like, just filled it from empty (8 mile left in the tank) and it took £45 of diesel and the display showed me this!

103658
 

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32 Posts
Fun little project this! I also have a R56 Dooper. However I did the exact opposite with the exhaust :D It came with a JCW rear bumper with the original side exit exhaust diffuser but I changed it to a GP2 diffuser and modified the exhaust by cutting it just before the bend, welded on a length of stainless pipe and mated it to an aftermarket back box with twin exhaust tips. Also manufactured new hangers since they were absent (obviously). Looks the business if I may say so myself.

Original
103674


Aftermarket backbox and GP2 diffuser
103675


Have since changed the tips to carbon fiber wrapped Akrapovic ones since I love the look but can't afford the full system 😅 And it wouldn't make sense on a diesel anyway.
103677


I also did a remap which made it a bit more fun. And a bunch of other mods as well 😄
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #37 ·
Had the exhaust not been so comical then I’d have got an aero bumper and put a diffuser on it but it was only fit for the scrap man

the TDI tuning box is on its way back so hopefully have that by Friday (if not tomorrow), what sort of power are you gettibg From your remap and does it make a big difference?
 

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Yeah it looked pretty shite tbh 😄

I've not had mine on a dyno but the estimate is around +30hp/+70nm or so. It makes quite a difference in day to day driving and when I finally did it I wondered why I didn't do it sooner. Worth every penny.

Been thinking of doing more like swapping turbo, downpipe etc but I'm thinking it might just be better changing to a S/Works instead. I've had this one for 10 years(!) and been super pleased with it but my situation has changed. I got it as a daily for commuting to work, hence going with a Diesel, but nowadays I don't commute and just use it for fun. Going on meets, nice drives and as many track days as I can manage. Plus the miles are getting up there. But it's been rock solid since I got it!
 

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Premium Member
2006 cooper S 221bhp
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765 Posts
Discussion Starter · #39 ·
I’m not doing anything engine wise to this apart from putting the cat back on as it’s been tampered with, this is my commute car so want to keep the MPG up and if I want a thrash I can take the R53 out

I was thinking about changing the wheels though and maybe a G wing but on the same hand I do like the understated stealth look it’s got now with the minimal mods
 

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2006 cooper S 221bhp
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765 Posts
Discussion Starter · #40 · (Edited)
Fitted the tuning chip this afternoon, had an issue with the instructions being terrible, the pictures on it were for a similar engine fitted to a different car, possibly a Ford and it was telling me to take the battery off etc but mine is under the scuttle vent so obviously different

ended up calling TDI tuning and they sent me a link to a video with the same engine as the mini on but in a different car again, but not a mini, it gave me the idea where the sensor I needed to plug into was and I eventually found it after removing the airbox and a few other bits and bobs, the sensor was a pain too as I couldn’t get to it with my fingers so had to blindly get a flat blade screwdriver under the tab and give it a pull!

it’s lurking under this lot!
103688


below the rubber pipe that’s attached to the plastic one
103689


anyway got it fitted after about 30 mins of messing about, I’ve only taken it a couple of miles in town but it feels like there is loads more torque in the midrange, can’t wait to try it out on the open road tomorrow morning, I’ve got to use it for work tomorrow night for work too so see how it performs on the motorway
103687
 
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