Engine and drivetrain

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2 Kent Auto Developments current range of tuning parts for the Mini and Midget demonstrates effectively the company policy of providing quality, reliability and performance from every item that carries the KAD name. The flagship of our range is the Alloy 16 valve Twin Cam conversion for the A series engine, providing power outputs of 140 bhp/litre in race trim and 100 bhp/litre in road tune. The main castings are sand cast in [99 alloy by Kent Aerospace Castings, whose strict quality controls ensure freedom from shrinkage and porosity. Two different castings are used to create a small valve head for road cars and a big valve for race use. Steel billet camshafts in a separate cam carrier operate the valves through EN4OB bucket cam followers with shims to adjust valve clearance. Valves, guides and seats, again in high quality materials, are all suitable for lead-free fuels, and the free breathing and good combustion characteristics of the KAD Twin Cam mean that exhaust emission levels are excellent with a correctly calibrated engine management system. It is possible to run the Twin Cam with either twin DCOE carburettors or with the Weber Alpha engine management system for which KAD is an agent. Various intake manifolding arrangements are available to cater for most requirements. After three years of development the KAD Twin Cam offers excellent performance with reliability when correctly built, installed and maintained. The KAD alloy Varidrum fills a gap in the market as a lightweight alternative to the cast iron drum. Cast in heat-treated LM25TF, the drum features a unique plasma-sprayed brake lining that is both extremely durable and lightweight at 1.8 kg each, with a conventional finned design ensuring structural rigidity and brake cooling. Available in standard, wide and extra-wide form, the Varidrum is a good long-term investment as the ease of respraying a worn lining means that these drums will likely outlast the car. The KAD-Narita Alloy rear radius arms, at 2.94 kg each, add a new dimension to the fight against unsprung weight in Mini suspension systems. Cast in L155 alloy, attention to detail has allowed a wide range of lightweight suspension and braking possibilities to unfold, including the ultimate set up for race cars using inboard coil

3 The KAD alloy flywheel solves the eternal problem with steel cranks and steel flywheels of fretting on the taper. By using a high-strength alloy billet, the reduction in peripheral weight and the detachable centre designed in a dissimilar metal to that of the crank both act to reduce the likelihood of fretting occurring. With the durable plasma-sprayed clutchbearing face the flywheel s light weight (3.6 kg) means less inertia and hence better engine response. Coupled with our alloy backplate (1.14 kg) the combination is an essential fitment for any serious race engine and should be viewed as an insurance policy for any steel crank. KAD Alloy four-piston callipers have been competition proven in both rally and race use with great success. Excellent stopping power and light weight (1.25 kg) combined with the availability of carbon metallic pads means that unsprung weight can be reduced significantly without sacrificing braking effort or cooling. The callipers are purpose-designed for single-pipe Mini fitment and are available in three sizes 12/13", 10" and Cooper S wheel in both solid and vented disc form as a bolt-on conversion. The 10" vented calliper can be supplied with TIJV approval if required. Aside from manufacturing, KAD can offer a complete engine building and in-house dyno testing service including development of two-stroke and four-stroke engines, race and rally car preparation, and are agents for the

4 Engine and drivetrain The flagship of our range is the 16 valve Twin Cam cylinder head conversion for the A series engine providing reliable power outputs of up to 140bhp per litre in race trim and 100bhp per litre in road tune. The castings are sandcast in L99 alloy which ensures freedom from shrinkage and porosity in these critical components. Two different head castings are made enabling small valve and big valve heads to be produced, optimizing the port and valve sizes to give good mid-range as well as top end power in each application The twin overhead camshafts are steel billet, belt driven from the crankshaft and run on EN4OB cam followers with valve clearances adjusted by shims The valves, guides and valve seats are unleaded quality The free breathing and easy combustion characteristics can be provided by using either a pair of 40 or 45 DCOE carburetors or the excellent Weber Alpha Engine Management System where low exhaust emission levels are an important criteria With either option, the broad torque spread means drivability remains excellent even with our full race engines The KAD 5 speed gearbox is designed for competition applications using face dogs on straight cut gears The gear train fits into a standard rod change casing with minor modification and is different to other Mini 5 speed units in being a true 5 speed box, direct in top gear, this means that there is minimal torque loss in fifth gear when compared to an overdriven 5 speed unit The gear change pattern has a dog leg first which leaves the 2nd, 3rd, 4th and 5th gears in a convenient H pattern The gears themselves are manufactured from 5156, an Aerospace VAR steel some 50% stronger than commercially available steels and the combination of high grade materials, short compact shaft lengths and a driver friendly slick gear change makes this gearbox the choice far serious competition use. The KAD alloy flywheel and backplate combines lightweight with the durability required for hard race usage. High strength alloys, CNC machined to precise tolerances ensure excellent balance and careful design with low peripheral weight and the detachable flywheel centre boss acts to reduce the likelihood of fretting on the crankshaft taper with steel crankshafts, thus the flywheel can be viewed as an insurance policy for the expensive steel cranks used in Mini race engines. Both the flywheel and the backplate use the race proven plasma sprayed friction face, the high coefficient of friction reducing clutch slip under power with the added advantage that warn friction faces can be resprayed and ground prolonging the lives of the components over conventional items. KAD s experience in building high powered A series engines has exposed weaknesses in standard components. Repeated failure of the standard keyed flywheel washer has lead to our manufacturing this component in EN24T steel, reinforcing this weak area.

5 Kent Auto Developments Ltd. 16 Valve Cylinder Head Conversion DOHC, belt driven from crankshaft, for Rover / BMC A series cylinder blocks of 1275cc and above. 2 versions: small valve and big valve. Small Valve: 4 valves per cylinder (27mm inlet x 23.7mm exhaust) suitable for road use with either 2 x 40 DCOE Weber carburettors or Weber Alpha Engine Management system. Standard power bhp, 140bhp with additional tuning. Big valve: 4 valves per cylinder (30.4mm inlet x 26mm exhaust) suitable for competition use with either 2 x 45 DCOE Weber carburettors or Weber Alpha Engine Management system. Power outputs from 140bhp to 1 80bhp according to degree of tuning or application. Must be used with 73.5mm or 74mm bore size and requires steel billet or forged crankshaft and conrods and uprated transmission. Both versions require the use of a high quality flat top piston to achieve adequate compression ratio, the pistons require machining for valve clearance pockets. We recommend the use of forged piston s. Engine bay modification s are minimal, but clearance is required over the cam timing pulleys, a GRP bonnet is available for round nosed Mini s. Popular Cam Profiles: KAD " cam lift, 264 degree duration suited to road use. Li " cam lift, 280 degree duration suited to fast road / hillclimb / rally / race. Li 0.408" cam lift, 306 degree duration suited to race use. Fi 0.412" cam lift, 324 degree duration suited to race use. BD " cam lift, 316 degree duration suited to race use. Race 5 Speed Gearbox Face dog engagement, straight cut gears. Fits Rover A plus casing (DAM5626) casing without modification. Ratio s ist gear 2.616:1 2nd gear i.989:1 3rd gear i.67i:1 4th gear i.294:1 5th gear i.000:1 Reverse 2.49i:1 Input and output shafts splines identical to standard Mini. Supplied as a self assembly gear kit with speedometer casing with extra bearing and centre oil pick up pipe. Kent Auto Developments Ltd. Brooker Farm, Newchurch, Romney Marsh, Kent TN29 ODX Tel: Fax: kadmini@aol.com

6 Mini Braking Systems KAD can provide an integrated braking system for both road and race Mini s, banishing the old myths of poor brakes whether the car uses the traditional 10" wheels or the later 12" and 13" fitments. Carefully designed, CNC machined four and six piston calipers, solid and vented discs and rear alloy finned brake drums allow powerful brakes without excess unsprung weight. By matching calipers and friction materials to master cylinder sizes, the correct combination of outright brake power and feedback to the driver can be achieved. The almost universal use of KAD brake products in Mini based competition bears witness to the fact that KAD brakes have become the standard by which other systems are judged. The KAD four pot caliper is a cast two piece design made in three disc fitments each available for solid or ventilated discs. caliper body provides a supremely stiff deflection under low pressure resulting in a firmer pedal and this permits the use of a smaller master cylinder giving higher line pressure and hence greater braking power without long pedal. The caliper uses differentially sized pistons in stainless steel to combat taper wear on the long thin pads which by running on the periphery of the disc maximize braking torque on a given size disc The narrow section of the caliper as bridges the disc allows the use of a larger disc than would be possible with a bolt together caliper, and under certain 10" wheels, the six pot caliper an run disc sizes as great as 8.4" diameter, which s the standard size disc for 12" wheels. The six pot can be used with either solid or vented discs from 7.9" to 8.4" diameter. The KAD alloy brake drum is cast in LM25TF and is a lightweight finned drum for rear wheel use which uses the same plasma spray technology for the friction lining as is used for the KAD alloy flywheels, resulting in a high coefficient of friction and a low weight penalty when compared with drums using cast iron liners, which can spin The calipers feature piston dust seals, stainless fasteners and bleed screws providing durability for road conditions as well as being suitable for all forms of Mini competition use. The three disc size fitments enable their use with most Mini wheels with disc sizes from 7.75" to 8.4" diameter. For road applications they are usually used with servo assistance, but in most competition use careful matching of master cylinders and rear wheel cylinders is used to get high line pressure with minimal pedal travel. KAD calipers and high friction carbon metallic brake pads have gained the reputation of being the tool for the last of the late brakers. The.KAD six..pot..calipers, whilst not specifically designed for road use, represent surely the ultimate development in Mini braking. Exquisitely CNC machined from a single billet of high strength 2014A aluminum alloy, the one piece as the drum heats up. With the added advantage of being reconditionable if the lining wears (through the use of hard competition shoe materials), these drums should provide a long service life. The drum features a built in 1" spacer.

7 Kent Auto DeveIopments Ltd. KAD 4 Piston Alloy Calipers Available in three versions for solid or vented discs. 1 2" caliper uses 8.4" diameter solid or vented disc for 1 2" and 1 3" wheels. 1 0" caliper uses 7.9" diameter solid or vented discs for most 1 0" wheels (except Mamba, Steel Cooper S and Mag Minilite) Mamba Caliper uses 7.75" diameter solid or vented discs for Mamba, Steel Cooper S and Mag Minilite or other 1 0" wheels where there may be clearance problems. All calipers have cast aluminium bodies, hard anodised for corrosion and wear resistance. Pistons are hard anodised aluminium. Brake pads are Metro Turbo Type A, available in a variety of compounds. Single line fluid feed, 3/8 UNF thread. Stainless steel caliper bolts and bleed screws. Supplied with mounting bolts and spacer washers to suit application, except Mamba caliper for use as Cooper S replacement with Cooper S disc and flange (please order separately). Weight less pads (solid caliper) 1.25kg. KAD Six Piston Alloy Caliper One caliper version, radially mounted, allows fitment with 7.9" to 8.4" diameter disc, either solid or vented. One piece caliper body CNC machined from 2014A alloy billet. Stainless steel pistons with differential sized bores to combat taper wear of pads. Pads available in Standard road, Mintex Ml 144, Ml] 66 and PF Carbon Metallic 83 compounds. Supplied with mounting bracket, all bolts and washers. Single line fluid feed, 3/8 UNF thread. Weight less pads and mounting bracket 1.17kg. Kent Auto Developments Ltd. Brooker Farm, Newchurch, Romney Marsh, Kent TN29 ODX Tel: Fax: kadmini@aol.com

8 Six Piston Brake Calipers Three different calipers are currently available according to brake disc diameter. The Type A calipers run 7.9" to 8.4" diameter solid or vented discs up to a maximum width of 21mm. The Type B caliper uses the same piston sizes and brake pads as the Type A caliper and is suitable for 9" to 10.5" discs. Both the Type A and B caliper are suitable for saloon or single seat race cars up to 900kg gross vehicle weight. The Type C caliper is suitable for heavier vehicles using 1 6" and 1 7" diameter wheel with disc sizes of between 300mm and 330mm diameter by 32mm wide. KAD has designed and manufactured a range of six piston alloy brake calipers, machined with one piece bodies from high strength 2014A extruded aluminium billets. This monobloc style of construction provides significant advantages over the conventional bolt together style, as the lack of a joint plane increases the overall stiffness of the caliper, and with lower body deflection under pressure, the pedal effort is used to clamp the brake pads to the disc as opposed to pushing the caliper apart. With lower deflection the bore size of the master cylinder can be reduced, which increases line pressure in the system without getting a long pedal which will result if a high proportion of the fluid displacement from the master cylinder is being used to compensate for the deflection of the caliper bodies. Without the need to bolt the two halves together, the bridge section which passes over the disc can be made to a narrower profile which means a larger diameter disc can be employed under a given wheel aperture. The brake pad shapes have a long length to depth ratio which moves the centre of the pressure on the brake pad out as far as possible on the radius of the disc, maximizing the leverage available on a disc of a given size. Long thin brake pads have a tendency to wear into a taper shape as the leading edge of the pad will bite harder on the disc than the trailing edge, to counteract this, the pistons are differentially sized to alter the pressure centre of the brake pad. The pistons are manufactured from stainless steel having a lower heat conductivity than aluminium, the piston seals are fitted to the back of the pistons to keep the hydraulic fluid away from the disc/pad heat source as much as possible to preventing brake fade. The calipers use a radial mounting system with a separate mounting block which allows their fitment to a wide variety of vehicle uprights and they can be mounted in either leading or trailing positions by substituting the fluid bridge pipes with the bleed screws.

9 Kent Auto Developments Ltd. KAD Six Piston Caliper: Type A Suits " diameter disc, 10-21mm thick. Stainless steel pistons, differential bores. One piece body machined from billet of 2014A aluminium, hard anodised for corrosion and wear resistance. Radially mounted caliper, 2 bolts 3/8 diameter on 109mm centres offset by 36.5mm from disc centre line. Single line fluid feed, 3/8 UNF thread requires banjo type fitting. Weight less pads and mounting bracket 1.1 7kg KAD Six Piston Caliper: Type B Suits " diameter disc, 10-21mm thick. Stainless steel pistons, differential bores. One piece body machined from billet of 2014A aluminium, hard anodised for corrosion and wear resistance. Radially mounted caliper, 2 bolts 3/8 diameter on 109mm centres offset by 36.5mm from disc centre line. Single line fluid feed, 3/8 UNF thread requires banjo type fitting. Weight less pads and mounting bracket 1.23kg. KAD Six Piston Caliper: Type C Suits "diameter disc, 30-32mm thick. Stainless steel pistons, differential bores. One piece body CNC machined from billet of 2014A aluminium, hard anodised for corrosion and wear resistance. Radially mounted caliper, 2 bolts 10mm diameter on 180mm centres offset by 30mm from disc centre line. Single line fluid feed, 3/8 UNF thread requires banlo type fitting. Weight less pads and mounting bracket 2.3kg. Kent Auto Developments Ltd. Brooker Farm, Newchurch, Romney Marsh, Kent TN29 ODX Tel: Fax: kadmini@aol.com

10 Mini Braking Components Rear Disc Conversion This has been developed in 2001 to fill the need for a lightweight rear disc brake conversion with an effective mechanical handbrake replacing the standard drum brakes at the rear. The calipers are a single piston sliding type, fully dust sealed, machined from billet aluminium. The hubs, carrying a lightweight steel drilled disc are CNC machined from billet aluminium and accept standard Mini wheel bearings. The kits are supplied complete with all of the parts to convert from drum to disc brake and use the standard handbrake cables. The kit will fit under 10" wheels and has been designed with both road and competition usage in mind. Weight 2.8kg Mini 4 pot billet alloy calipers: The calipers are CNC machined from HE3O (6082) extruded billets, which has improved the caliper body stiffness over our previous sand cast caliper. The pistons are anodised aluminium and are fitted with dust seals. Fluid feed is via a single 3/8UNF fluid feed port. Stainless steel bolts and bleed screws are used throughout. Weight less pads 1.26kg Pads available in the following compounds: Standard road, EBC Green, EBC Red, Mintex M1144, Carbon Metallic 83 compound " solid disc " solid disc /7.75" solid disc " vented disc " vented disc /7.75" vented disc Mini Big Disc kit Our four pot caliper will fit disc sizes upto 8.4" (2 13mm), where 13" wheels are used, and a no compromise front brake setup is required our big disc conversion can be used. This combines our one piece Type B caliper with a 265x18mm vented disc with separate alloy mounting bell KAD Adjustable bias pedal box Horizontally mounted, fabricated pedal box which bolts to existing brake master cylinder mounting studs, facing forward into engine bay. Enables the use of independent front and rear master cylinders with a balance bar assembly to adjust front to rear bias pedal box integral reservoir master cylinders cable adjuster KAD Ltd tel fax sales@kad-uk.com wwwkad-uk.com

11 Mini Suspension KAD s range of suspension parts aims to reduce unsprung weight in the suspension and driveline to ensure that the tyres remain in contact with the road surface over bumps, through corners and under acceleration and braking. Whilst lightweight components reduce the overall weight of the vehicle, it is the masses which are unsprung such as the wheels, suspension uprights, brakes, discs and shafts where the most important gains will be achieved in the vehicles handling. KAD s alloy rear swing arms are produced in a sophisticated aluminum alloy Li 55, which features both high strength and good stiffness, but also good ductility or springiness. It is this toughness that allows them to take the punishment that competition use places an suspension parts. The arms are produced in two versions, lightweight and ultra lightweight. Lightweight being exactly half the weight of a standard steel arm and is suited to light road use, rallying, sprint, hill climb and heavy circuit use, whilst the ultra lightweight is used far genuinely feather weight race vehicles. Both arms are compatible with either conventional rubber cone or coil over suspension systems and KAD produces it s awn stub axles with 1/2" diameter studs to permit coil aver damper units to be fitted to the arms without compromising strength. KAD s rear alloy suspension hubs, CNC machined from high strength 201 4A alloy are again half the weight of the standard steel hub and are compatible with the Timken type taper bearings. The alloy top sub-frame mountings prevent unwanted lateral movement between the sub-frame and the body of the late Mini s where the over enthusiastic use of rubber vibration mounts by the factory allows the sub-frame to almost steer itself in a powerful Mini. Solid front sub-frame bushes take this process a stage further, holding the front of the subframe in place. The KAD alloy handbrake quadrants are a lightweight alternative to the rusting standard steel items usually found nestling under years of grime, and are the perfect compliment to a pair of KAD alloy trailing arms. At the front of the car, KAD s adjustable front tie rods allow adjustment of castor angles without removal of the tie rod from the car. The rod section is made from EN16T steel and has a greater resistance to bending than the standard items. The lower arm mount and the chassis mount are both machined from solid to maximize strength as some of the fabricated mounts on the market have proven to be dangerously weak under competition conditions. KAD manufactures several anti-roll bars to help control body roll with both road and race cars, two front bars are available, 5/8" diameter for either road use with non rod end tie rods and a race type which mounts via a pair of weld-in bushes. The rear bar allows fitment independently of the sub-frame so can be fitted whether the sub-frame is retained or not. All of the KAD anti-roll bars have been designed to fit neatly underneath the car, avoiding the likelihood of the bars being damaged on off road surfaces

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