BMW MINI CONVERSIONS

With Over 20 years working on forced Induction and naturally aspirated engines we are the Specialists! Remember at BBR-GTI the masters of going faster you're in safe hands! See Brodie Report for a short note on forced induction road tuning relating to the BMW Mini Cooper S and a Note for Cooper S pre 2005 model owners with supercharger pulley reductions, also see our BBR Phase Two Versus BMW Mini Cooper Works comparison.

BBR Mini Accessories
BBR BMW Mini Cooper S DIY parts list
BMW Mini One & Cooper: Phase 1
BMW Mini Cooper S - including 2005 model year: EVO-2 Software Phase 1 Phase 2 Phase 3 Phase 4 & The New Phase 5 - BBR Cooper Turbo

Our dyno tested 220 to 312 BHP engine power, and suspension conversions, are designed to suit most sane drivers requirements, now if there are any "loons" out there wishing for 'more' power we have evolutionary ideas for tuning the BMW Mini Cooper S to really turn it into a blindingly fast missile! At BBR we like a challenge, try us?

BBR MINI COOPER S EVO-2 SOFTWARE ONLY
When we designed our 220 to 275BHP Cooper S conversions we mapped the ECU's accordingly to achieve the best possible power and economy. Looking back we realised we had ignored the possible advantages from modifying the manufactures original software on an unchanged mechanically (standard) car. As a new BBR starting point to Cooper S tuning we have recently carried out extensive engine dyno testing to improve the original software. We realise not all of you out there want another 40+ BHP, most would be happy with another 18BHP, far crisper throttle response and improved engine vitality. Now here's the magic part, with our new software installed, as an addition to the increase in performance, the engine which guzzles fuel in its original form now has far, far better fuel economy! Our own demo Cooper S returns well over 300 miles per tank full and will average up to 39MPG and that's with DB driving, and he doesn't mess about!

Our Cooper S now achieves a free tank of fuel after every 6 fill ups! (compared with the manufactures software)

Price Fitted While-U wait just £349 - and remember this is totally undetectable, it's your BBR's secret...!

Now recently we've heard guy's with Cooper S's on the phone telling us that so called Cooper S tuning experts are claiming a whacking great 25 - 30BHP from just a software modification..!!!! (please also see Cooper S Beware of BS!).

So here's the BBR challenge: if any of these so called experts can prove on our engine dyno (free of charge) that they can achieve on pump fuel a gain of over 18BHP (let alone 30BHP) from just changing the software (from the original manufactures). They can win free of charge our new 2005 Cooper S model with a list price of £24 000!!! We await the first phone call (LOL).

BBR MINI COOPER S PHASE 1 220

Our BBR 220 Conversion transforms the BMW Mini Cooper S into the car it should have been from the start! Quote EVO magazine November 2003:

"The figures tell the story. The BBR car monsters everything else here" (seven competitors modified BMW Mini Cooper S's) "the pace just piles on and on, as that extraordinary 16.1 seconds 0-100MPH time shows."

With 218BHP @ 6750 and 196LBFT torque @ 5100 we promise you an exiting drive home!

Our BBR 220 Mini conversion, along with all our engine conversions have been developed and tested on our in-house Superflow 7100 dyno, which is the finest DYNO in private hands, in the UK. We have also vigorously road tested the BBR 220 Mini under all conditions, including track. We believe our 220 conversion to be the most comprehensively engineered and tested mini conversion available, in short there are none as well engineered, reliable and cost effective!

Don't believe us! Come and try our demonstrator for yourself!

The "BBR Mini 220" Conversion comprises four elements:

1. Installation of BBR Star*Chip EVO-2 Software

These new modified software maps have been painstakingly developed both on our dynamometer and on the road over a number of months and consist of the following changes to the original BMW Mini Cooper S software:

• BBR modified Ignition Maps

• BBR modified Fueling Maps

• BBR modified Air Flow Correction Maps

• BBR modified Engine Anti-knock (pinking) Correction Maps

• NEW Optional BBR modified TCS (Traction Control Maps), minimizes torque reduction on engine under wheel spin, removing sudden cut of engine power.

Our new software provides smooth acceleration throughout the rev range both on and off boost. As an extra safety margin we have reduced the ignition at the top end of the rev range, which gives driving at 140MPH+ on full boost full engine protection*.

We have also allowed a good safety margin in the ignition maps for poor quality fuel. *For maximum (full boost) performance we recommend that your BBR Mini 220 is run on good quality fuel such as Super + (97 octane +) or Shell Optimax. However, for normal (not "full boost") driving, regular unleaded fuel is satisfactory. Every BBR Cooper S has the benefit of individual BBR custom software to achieve the best on road result.

2. Installation of BBR Supercharger drive pulley

The Standard MINI pulley is removed, and replaced with a BBR-manufactured pulley. The BBR pulley is machined from aircraft spec dural (unlike others we have seen) too ensure long and reliable service and belt life.

3. Installation of BBR / Cosworth drive belt idler

The Original idler is removed (we found it to be a little unreliable) and our BBR modified high quality Cosworth idler installed.

4. Changes to the boost and intercooling delivery systems

We fine tune the original boost intercooler installation when installing our Mini 220 conversion.

5. As a cost effective further option at this Phase, have our specially developed BBR camshaft installed for just an additional £285 (no fitting charge).

Price Fitted While-U wait £1295 inc labour, please see our Optional extras.

Own a previously converted BMW Mini Cooper S?

Don't worry! At BBR we can sympathetically re-engineer alternative upgrades to our Phase one BBR 220 specification for £795. We can also fit our S/S exhaust system, BBR PowerGrip suspension kit and our ram induction bonnet venturi.

BBR MINI COOPER S PHASE 2 240
The BBR Phase Two is for those drivers who want more out of their BMW Mini Cooper S than a Phase One can offer but who don't (yet!) want the raw power of a Phase 3 and 4 conversions.

The Phase Two comprises Phase One with the addition of our big valve, ported and gas flowed cylinder head with matched manifolds to suit, new gaskets and seals, plus our specially developed BBR camshaft and individually mapped BBR software. It all adds up to a scintillating free revving conversion that will provide you with endless fun!

241BHP @ 6950 and 214LB FT torque @ 5200

Price Fitted £4750 inc labour (please allow 5 working days) please see our Optional extras

Overseas customers please contact us for kit price.

BBR MINI COOPER S PHASE 3   255
The BBR Phase Three includes phase 2 with the addition of BBR's twin high flow intercooler assembly. The conversion maintains the original top mounted intercooler and in addition uses a secondary front mounted cooler. This includes all related pipe work, clamps and fixtures, and as with all our conversions BBR custom mapped software.

Here is our dilemma with the original BMW Mini Cooper S intercooler system. During all our dyno cell testing, the inlet charge temperature never exceeded 40 degrees C, yet in car temperatures show a minimum of 50 degrees C and temperatures as high of 90 degrees C! With the BBR twin intercooler assembly installed an ideal average 30 degrees C inlet charge temperature is maintained under the most vigorous driving conditions and temperatures, giving you maximum power 100% of the time! Rolling road's are a temperature nightmare, for power testing, stay off them!

What are we saying? It's simple, it matters not who is tuning your BMW Mini Cooper S, every conversion available (including the official works conversion) gains extra power by increasing boost pressure levels, increasing boost (compressing air) creates extra heat. That extra heat needs to be dissipated to efficient levels to maintain engine power and eliminate power loss.

253BHP @ 7000 and 229LB FT torque @ 5200

Price Fitted £6745 inc labour (please allow 5 working days), please see our Optional extras

If you choose to install our high flow twin intercooler assembly between Phase one and two, we are happy to oblige.

BBR Twin high flow Intercooler Assembly Price Fitted £1995 inc labour 

Overseas customers please contact us for kit price.

BBR Cooper S Phase 3 Components Including:
BBR Big valve ported Cylinder head & BBR Camshaft
BBR Twin high flow Intercooler kit
BBR Cosworth Idler, BBR high speed pulley, BBR modified ECU

OPTIONAL EXTRAS for the BBR PHASE 1-3

BBR Ram Induction Bonnet Air Inlet Venturi kit

Increases air inlet pressure by 8% and reduces the inlet charge temperature at 100 mph by no less than 10 degrees C! Its a must!

Price £79 and free of Charge from fitted Phase 2+

BBR S/S Exhaust System

Installation of double "twin exit" exhaust system from the catalytic converter back, with twin deflector rear valence panel

Price Fitted While-U wait £795

BBR PowerGrip suspension kit (click for more info)

This consists of altered suspension geometry and front and rear ride levels. This amazing suspension conversion allows for full throttle corner exits so, for example, you can now drive out of roundabouts on maximum power (conditions permitting) without the usual understeer.

Your new suspension will give you maximum front end grip, you can even get the rear end out a little - great fun. A "must" for track days. Price Fitted While-U wait £495 inc labour, DIY Pack £395 + Shipping

BBR Limited Slip Differential
Using clutch and ramps, this diff as opposed to all others available, works under all road and track conditions. Eliminates unweighted wheel spin, delivering instant drive to the weighted wheel. On track this will provide precise driving and full throttle corner exits. On the road in conjunction with our PowerGrip suspension your BMW Mini Cooper S will out perform any car you come against, giving you stunning agility in corners! Price Fitted £1295 inc labour, DIY £795 + Shipping

NEW BBR solid tappet assembly (click for more info)
BBR's solid tappets, a must for all high reving BMW MINI petrol engines. Totally removes the risk of hydraulic tappet failure.
Price per BBR solid tappet assembly £795
Add £200 for BBR uprated double valve springs.
Note: The tappets are best fitted with cylinder head on the bench as the tappets will need final grinding to achieve tappet to valve stem clearance, we supply full fitting instructions.

BBR MINI COOPER S PHASE 4 275
The BBR Phase Four conversion is a full package of engine, transmission, suspension, brake and tyre modifications. This is the flagship of our supercharger conversions aimed at those who prefer the driving characteristics of a supercharger over a turbo. This is the ultimate supercharged MINI, which will shock even the most expensive super cars and give them a run for their money! be warned this is serious motoring! Which is guaranteed to put a permanent smile on your face!

Engine Specification

• BBR Big valve, gas flowed and ported Cylinder head fitted with BBR camshaft
• BBR Solid tappet and uprated valve spring assembly
• BBR modified high mass air flow supercharger assembly (we ditch the original supercharger)
• BBR modified high flow fuel system and injectors
• BBR auxiliary high flow water pump assy. and redesigned coolant system
• BBR fixed tension belt drive assembly
• BBR high flow twin intercooler assembly
• BBR S/S exhaust system
• BBR Ram Induction Bonnet Air Inlet Venturi kit
• and of course BBR custom mapped software

Transmission/Suspension/ Brake and Tyres

• BBR Limited Slip differential
• Optional BBR revised gear ratios 
• BBR PowerGrip suspension
• BBR big brake conversion, AP 4 pot callipers with fast road pads with ventilated drilled discs, and replacement S/S braided hoses (fits std 17" wheels)
• BBR fitted Goodyear F1 road tyres

Price Fitted £14995 inc labour (please allow 15 working days)

272BHP @ 6800 and 256LB FT torque @ 4100

BBR MINI COOPER S PHASE 5 - THE ALL NEW BBR COOPER TURBO 300
Our new flagship turbo conversion, again a full package of engine, transmission, suspension, brake and tyre modifications, but this time something's a bit different! The inefficient supercharger has been removed and replaced with our BBR cast manifold and hybrid turbo! The standard top mounted intercooler is ditched in favour of our unique BBR Ram-Air, air box. In addition there are 3 progressively higher boost settings automatically controlled via load and throttle position, this ensures progressive and smooth acceleration, under all conditions, even through town! Our Ram Air system spools the turbo quickly, giving lightning fast throttle response which all in all adds up to a truly electrifying drive. We believe this is the most powerful BMW mini world wide, with over 300BHP and aimed only at the serious driver! For the full story behind the BBR phase 5 please click here.

Engine Specification

• BBR Big valve, gas flowed and ported Cylinder head fitted with BBR camshaft
• BBR Solid tappet and uprated valve spring assembly
• BBR Cast manifold and hybrid turbo
• BBR Ram-Air air box, pipe work and filter
• BBR modified high flow fuel system and injectors
• BBR 3 stage boost system
• BBR auxiliary high flow water pump assy. and redesigned coolant system
• BBR front mounted high flow intercooler
• BBR S/S exhaust system
• BBR Ram Induction Bonnet Air Inlet Venturi kit
• and of course BBR custom mapped software

Transmission/Suspension/ Brake and Tyres

• BBR Limited Slip differential
• Optional BBR revised gear ratios 
• BBR PowerGrip suspension
• BBR big brake conversion, AP 4 pot callipers with fast road pads with ventilated drilled discs, and replacement S/S braided hoses (fits std 17" wheels)
• BBR fitted Goodyear F1 road tyres

Price Fitted £POA inc labour (please allow 20 working days)

312BHP @ 7050 and 271LB FT torque @ 4300

BMW Mini One & Mini Cooper
We also have designed tuning packages for these models (e.g. Mini One: extra 25 BHP while you-wait). Other mod's include camshafts, big valves, exhaust system and of course our PowerGrip suspension kit. But what the hell? Trade it in for a BMW Mini Cooper S and get into the fast lane!