visors too wide!

[bravekozak]

circlip install

I cut the Festiva visor mount with a utility knife, down to where the Mini arm groove was visible. I only had some 7mm circlips. The circlip would have to be streched to .330" which was too much. I will change up to a bigger circlip tomorrow. The circlip keeps the visor in place an snug.

http://bwbronze.com/festiva/circlip.jpg

The proper steps for modification are:
1) tilt the vise to the proper angle to end mill a 1/2" recess
2) ream the hole with a #6 taper pin reamer
3) then ream only to about 1" up a #7 taper pin reamer
4) cut the visor mount stem down with a utility knife
5) install a 5/16" circlip

It looks stock and works great!
Now, I just have to install some connectors and pull a couple of wires across from visor hole to visor hole and then down the A-pillar

[Festiva_tunner]

looks like its comming along - cant wait to see lit pictures

[bravekozak]

vitara

I didn't get the Cooper visor retainers from eBay. After a lot of searching, I have determined that the Vitara retainer had the best fit (smaller) and price (free). The butterfly mounts were a beast to remove. I had to use shears to cut them out.

http://bwbronze.com/festiva/vitara.jpg

Too bad I won't be using them. After determining where it will be mounted, I discovered that I will have to bump it out, just like the visor mount, so that it will be level and not grind against the headliner. I'll tack in a small solid piece of steel and thread the mounting hole.

http://bwbronze.com/festiva/visor3.jpg

Too bad it hits the mirror. It wouldn't if there wasn't such big holes at the corners of the header between the A-pillars. I am not wasting time filling them in and then making a filler plate for the stock mount. The Festiva header is like Swiss cheese. It isn't very strong.

I already tested to make sure the lights are working properly.

http://bwbronze.com/festiva/minilight.jpg

[bravekozak]

Smart mirror

I have to do something about the visors hitting the mirror.
So, I went on the Bay and did a buy it now.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=170244276866&viewitem=

I will update this thread after I receive the item and measure the swivel ball.
The Smart mirror is very narrow and triangular in shape.
I hope it fits.

[Aaronbrook37]

Awesome... this looks promising. I'm always bothered by the mirror being too vertically narrow compared to the size of the glass in the hatch... this looks like it may solve that issue!

[bravekozak]

eyeball

You are correct about the size of glass in the rear hatch.
At present I have a Kia Spectra mirror installed. It is slightly wider vertically and has an identical ball size for use in the Festiva mount.

I have only eyeballed the ball from outside the Smart windshield. It will be very close in size to the Festiva. The goal is to use the Festiva mount with the Smart mirror.
To give you an idea of what the mirror looks like in the Smart car, check out this online picture:

http://www.roadapples.org/Smart%20Car%20Interior.jpg

I only have to clear about a half an inch each side of the Mini visors.
I think it will work. Keep your fingers crossed.

[bravekozak]

15mm

I still haven't found out what the stock pivot ball size is on the Smart car.

http://www.tuningbase.de/epages/61800551.sf/de_DE/?ObjectPath=/Shops/61800551/Products/17080814/SubProducts/17080814-0001

http://www.evilution.co.uk/606

I hope it's the same as the Festiva/Kia - 15mm.
I should know in a couple of days.

[bravekozak]

16mm

I just received the bad news. The Smart ball size is 16mm. It is exactly 1 mm larger in diameter than the Festiva. It would have been better if it were smaller, then I could have removed material from the metal Festiva ball. I am going to find a place to cry now.

I wonder what would happen if I dipped the tip of the ball quickly in and out of some molten aluminum at the foundry?

[Aaronbrook37]

I would recommend something easier to manage. For example, a quick wrap of electrical tape may solve your issue, and once you get it worked in and maybe lubricated, it could fit really well.

[bravekozak]

197mm

I will try the tape first after I get the mirror. The Smart mirror was sent to the wrong address. I will have to wait a little longer.

The Smart mirror is 197mm (7-3/4")at its widest point. Both the Festiva and the Kia Spectra mirror are 9-3/4" wide. This will give me 1" of extra clearance on each side. More than enough room. I only needed half an inch on each side to clear rhe lighted Mini Cooper visors mounted in the stock Festiva visor mounts.The Smart mirror will also follow the line of the Cooper visor, which flares slightly outward. Unlike the Festiva visor, which flares sharply inward. I am now certain that the installation will look stock.

[bravekozak]

operation

I dissected a Smart mirror.

http://bwbronze.com/festiva/smart.jpg

It's all plastic with a spring steel retainer. The Festiva ball is indeed one millimeter smaller and fits into the Smart ball without any force. The 16mm Smart ball snaps into the socket. I will try some tape and report back in a future post.

[bravekozak]

test fit

I decided to see how tight the fit was with the Mini visors and Smart mirror.

This is what they look like with the visors down.

This is what they look like with the visors up.

They just barely brush the edges of the mirror. I went to Downtown Mini and bought two grey visor holders ( Mini part# 51-16-1-494-038 ) @ $9.54 each. They are the only ones with the proper fit. I will drill the holes for them, then feed the wires for the mirror lights and finally reinstall the headliner.

[Aaronbrook37]

Do I still owe you any money, Dan? LMK!

[bravekozak]

tape trick

I wrapped the ball with tape like you said. It does take a few seconds to sag into position after you adjust it. I will probably dip the ball in some epoxy as a test. I need something a little harder with more friction. Thanks.

http://bwbronze.com/festiva/test%20_fit.jpg

[crazyrog17]

That sounds like a good idea. You could always sand off the epoxy if that doesn't work out.