BigErn
Member
- Messages
- 29
My 2wd Sapphire Cosworth ongoing project.
Mostly copied and pasted from another forum I use cos I cant be bothered to re-write everything.......
My current Sapph was bought originally as nothing but a stop gap to play in while I was building/resto'ing my other 2wd Sapph I had at the time. However as I didnt have a place of my own to keep the work in progress it ended up being broken for bits and I kept some stuff for myself, sold others and weighed the rest in.
That then left me with the Sapph I still own now which previously belonged to Alps Pacino off here and I was happy to use and abuse it in its stage 3 form for a while. It then progressed to greys and an MSD chip with ALS/LC and I had great fun scaring old people and generally driving like a utter tit in it. It lasted much abuse with its only issues in the whole time being it needing a phase sensor and a crank pulley replaced.
Croft 2009 came round and I was starting to get a little bored of the car, it felt slow and I wasnt using it much the past 2 or 3 months. I drove it to the show and had a wander about but it was evident my interest in both my car and RS's in general was sparse to say the least.
I drove home and it was parked and not moved again till its MOT was due a couple of weeks later. It didnt pass as it needed welding, brake pipes and fuel pipes. I bought my M5 and that really was the death of the Cossie. There the car sat for months without being looked at again, it just got ignored as I walked past it every day.
Around late November that year a friend of mine was asking about the car and if I'd sell it. He came for a look and we agreed a price but he wanted to come back once the battery was charged and hear it running before we shook hands on the deal. A week or so later I went out and bought a new battery for it as the old one would show 12v once charged but would barely bring on the ignition lights. New battery fitted and it fired up first turn of the key with no rattles, taps noises or smoke. it just sat and gurgled at me and I fell in love with it again
I called my mate and told him I'd changed my mind as it wasnt really for sale in the first place and he'd just twisted my arm there and then and he was fine with being told he couldnt have it. So I sent it to a mates garage for the required work for its MOT and a few days later it was once again ready to play out again. I taxed it the following day and was loving being back out in it but it lasted 64 miles and the T34 shat itself, it wouldnt boost at all and the amount of smoke that was coming out of the back would have impressed James Bond
. Slightly disheartened I parked it up again and looked for another T34 to chuck on it so I could go out and kick its tits in again. One turned up locally and I went and bought it, it was mint with no play and looked relatively new, and fitted it the next day. Unfortunately it would make no more than 24psi and after driving it no more than 10-20 mile I took the hose off and had a wiggle of the shaft and discovered there was a lot of play and the compressor blades were catching on the housing. I rang the lad I bought the turbo off and told him what it was like and said I'd call up with the turbo on the car and show him. After a bit craic with him we agreed that he'd give me my cash back as he assured me the turbo was "mint" when I bough it. Cant say fairer than that.
After that I was ****** off with the car again and Lawnsy and I were talking about the spares I had in the garage and bits I had collected for the Sapph I was previously building and he talked me into taking my engine out and giving it a freshen up for a new spec.......
So not ones to hang about, about an hour and a half later we had dragged the car round his garage and this was what we were lookin at.....
The car sat for a while as it was summer and I was too busy playing on my R1 to work on the car and was saving up as much as possible to pay for bits etc.
Well I got knocked off the damn thing in Juy and while I was off on the sick I decided to do some odds and sods with the YB instead of sitting feeling sorry for myself.
Degreased and cleaned up some engine parts ready for painting
Block was pressure tested, gasket surface checked and bores honed.
Had to remove a lug from the block as it will be running an alternator drop bracket when rebuilt
Then it was time to get rid of the nasty Hammerite that was flaking off it
Etch primed then 2 wet coats of hi build
Painted in Ford Mercury Grey
CNC machined head for some extra air flow
Standard head on the right
Painted a few things cos Im not into shiny underbonnet stuff. I can never be bothered to keep it clean.
Mock built the inlet with some spare injectors and throttle body just to see how it looked together
I decided to remove the front pipe so I could get a Lambda boss fitted for my wideband. After a bit wiggling and jiggling I couldnt get it seperated so decided Id take the full system off and seperate it off the car.
Took a couple of pics of the underside while I was there.
I knew the nearside rear leg was patched for its last MOT and knew the rest of the leg it wasnt gonna be in good shape after standing in the elements for so long as it was touch and go back when it got welded. So I had a bit of a prod and poke about at it, as you do.....
Around top of spring has had welding before I got the car and has a little hole next to it again
Above the beam I managed to prod a fair sized hole
Finally the rear part of the leg is going on the seam and also a patch on the inner quarter of the boot floor, near where the vent flaps are
I decided to whip the back bumper off and take the lights out to see if they were hiding any nasty surprises too. Fortunately they werent.
I decided to drop the tank too, just for a look underneath
May as well drop the diff while Im there
Next was the prop and box out
Only a little bit of surface ginger on the front end, nowt to worry about there.
Had a look behind the wheel arch liners to see what the inner wings are like.
A little more painting stuff was done while waiting to get the underside welded up, Ill get round to it one day.
Fuel pump cradle
Gearbox cradle
Home made solid diff mount.
Diff
Fuel tank
Gearbox
Tank strap
LC-1 Wideband kit to wire up
Now for some mechanical progress at long last.
Everything new in the bottom end bar the rods and crank. Ford massively over engineered the OE items so no need to change till big power.
Where do all these go again??
Starting to look a little bit like an engine again now
I repainted the cam cover as it was done a long time ago and was pretty crap.
Cover painted grey and masking to paint the raised bit.
Not the best pics due to only being from the phone but you can see the finish is decent considering its only done with aerosol.
Thats the story so far so hopefully as I progress Ill remember to update it on here.
Just incase I dont then you can follow it on PassionFord.com via this link
http://passionford.com/forum/restor.../382230-my-sapph-e922-lbt-11-08-2011-a-2.html
Mostly copied and pasted from another forum I use cos I cant be bothered to re-write everything.......
My current Sapph was bought originally as nothing but a stop gap to play in while I was building/resto'ing my other 2wd Sapph I had at the time. However as I didnt have a place of my own to keep the work in progress it ended up being broken for bits and I kept some stuff for myself, sold others and weighed the rest in.
That then left me with the Sapph I still own now which previously belonged to Alps Pacino off here and I was happy to use and abuse it in its stage 3 form for a while. It then progressed to greys and an MSD chip with ALS/LC and I had great fun scaring old people and generally driving like a utter tit in it. It lasted much abuse with its only issues in the whole time being it needing a phase sensor and a crank pulley replaced.
Croft 2009 came round and I was starting to get a little bored of the car, it felt slow and I wasnt using it much the past 2 or 3 months. I drove it to the show and had a wander about but it was evident my interest in both my car and RS's in general was sparse to say the least.
I drove home and it was parked and not moved again till its MOT was due a couple of weeks later. It didnt pass as it needed welding, brake pipes and fuel pipes. I bought my M5 and that really was the death of the Cossie. There the car sat for months without being looked at again, it just got ignored as I walked past it every day.
Around late November that year a friend of mine was asking about the car and if I'd sell it. He came for a look and we agreed a price but he wanted to come back once the battery was charged and hear it running before we shook hands on the deal. A week or so later I went out and bought a new battery for it as the old one would show 12v once charged but would barely bring on the ignition lights. New battery fitted and it fired up first turn of the key with no rattles, taps noises or smoke. it just sat and gurgled at me and I fell in love with it again
I called my mate and told him I'd changed my mind as it wasnt really for sale in the first place and he'd just twisted my arm there and then and he was fine with being told he couldnt have it. So I sent it to a mates garage for the required work for its MOT and a few days later it was once again ready to play out again. I taxed it the following day and was loving being back out in it but it lasted 64 miles and the T34 shat itself, it wouldnt boost at all and the amount of smoke that was coming out of the back would have impressed James Bond
After that I was ****** off with the car again and Lawnsy and I were talking about the spares I had in the garage and bits I had collected for the Sapph I was previously building and he talked me into taking my engine out and giving it a freshen up for a new spec.......
So not ones to hang about, about an hour and a half later we had dragged the car round his garage and this was what we were lookin at.....
The car sat for a while as it was summer and I was too busy playing on my R1 to work on the car and was saving up as much as possible to pay for bits etc.
Well I got knocked off the damn thing in Juy and while I was off on the sick I decided to do some odds and sods with the YB instead of sitting feeling sorry for myself.
Degreased and cleaned up some engine parts ready for painting
Block was pressure tested, gasket surface checked and bores honed.
Had to remove a lug from the block as it will be running an alternator drop bracket when rebuilt
Then it was time to get rid of the nasty Hammerite that was flaking off it
Etch primed then 2 wet coats of hi build
Painted in Ford Mercury Grey
CNC machined head for some extra air flow
Standard head on the right
Painted a few things cos Im not into shiny underbonnet stuff. I can never be bothered to keep it clean.
Mock built the inlet with some spare injectors and throttle body just to see how it looked together
I decided to remove the front pipe so I could get a Lambda boss fitted for my wideband. After a bit wiggling and jiggling I couldnt get it seperated so decided Id take the full system off and seperate it off the car.
Took a couple of pics of the underside while I was there.
I knew the nearside rear leg was patched for its last MOT and knew the rest of the leg it wasnt gonna be in good shape after standing in the elements for so long as it was touch and go back when it got welded. So I had a bit of a prod and poke about at it, as you do.....
Around top of spring has had welding before I got the car and has a little hole next to it again
Above the beam I managed to prod a fair sized hole
Finally the rear part of the leg is going on the seam and also a patch on the inner quarter of the boot floor, near where the vent flaps are
I decided to whip the back bumper off and take the lights out to see if they were hiding any nasty surprises too. Fortunately they werent.
I decided to drop the tank too, just for a look underneath
May as well drop the diff while Im there
Next was the prop and box out
Only a little bit of surface ginger on the front end, nowt to worry about there.
Had a look behind the wheel arch liners to see what the inner wings are like.
A little more painting stuff was done while waiting to get the underside welded up, Ill get round to it one day.
Fuel pump cradle
Gearbox cradle
Home made solid diff mount.
Diff
Fuel tank
Gearbox
Tank strap
LC-1 Wideband kit to wire up
Now for some mechanical progress at long last.
Everything new in the bottom end bar the rods and crank. Ford massively over engineered the OE items so no need to change till big power.
Where do all these go again??
Starting to look a little bit like an engine again now
I repainted the cam cover as it was done a long time ago and was pretty crap.
Cover painted grey and masking to paint the raised bit.
Not the best pics due to only being from the phone but you can see the finish is decent considering its only done with aerosol.
Thats the story so far so hopefully as I progress Ill remember to update it on here.
Just incase I dont then you can follow it on PassionFord.com via this link
http://passionford.com/forum/restor.../382230-my-sapph-e922-lbt-11-08-2011-a-2.html