Welcome to my project thread, I've been working on and off, on this project for the last year with the intention of having it ready for summer 2011.
This is a standard 190e 2.3 16v, some refer to them as Cosworths due to the Cosworth cylinder head, I'm not sure about the credibility of claiming it to be a 'Cozzy' on account of an engine part, but there's no mistaking 185bhp from a 4 cyl 2.3 back in 1986 was pretty impressive.
Anyway, the intention being a stripped out track car loosely based on the DTM (deutsche tourenwagen meisterschaft) race car of the 80's
So, a full strip down and shell repair ready to receive:
- stock but fully rebuilt engine
- electronic fuel injection to replace the Bosch K Jet system
- 6 pot brabus brakes to the front and 4 pot brabus to the rear, larger grooved and vented disks obviously
- 17" ronal wheels with 888's or proxy T1r's
- complete new h&r cup suspension (ditch the self levelling rubish)
- roll cage and carbon race seats
- harnesses
- all salvaged parts blasted/dipped/cleaned, re-finished and re-bushed
- full geo' alignment and corner weighting
hoping to have it around 1000kg's and 190-200bhp but most importantly, handling well and reliable.
here's where it all began:
Collection from Perth, Scotland
back home, on stands and wheels off ready for assessment:
idea of the work ahead:
front of the car stripped:
left light well:
right light well:
inner wing:
cill at drivers door:
cill at rear arch:
below rear window:
inside boot to rear arch:
interior out and not looking too shabby
prod around underneath and and floor pan is in good shape
now call me insane, but this doesn't seem too bad to me
rear of the car and light wells not too bad
spare wheel well surface rusty but nothing poked through
So, front suspension and steering stripped and duly binned
Ground away some rust to find that the wishbone mounts are good, both sides
But the N/S spring top mount needs some work
Fortunately the shock top mounts are good, only surface rust
Corner of the inner wing not as bad as the other side
And amazingly the N/S cill is solid!
Rear of the car on the under side basically good
Nothing salvagable, all ordered
Things like wishbones I've got from a breaker and they were in very good condition, but I've still sent them off to have the bushes and ball joints popped, powder coated and re-bushed.
With the inner arches treated and sealed, new suspension, brakes and refurbed other bits, it should look quite nice down there at some point hopefully soon.
Cleaned up arches
It'll get a new clutch anyway, so that should be an easy job, I've also got a short shift kit for it.
next job was to remove the radiator and oil cooler:
the engine and bay would deffo benefit from a full clean and tidy up to make it look trick (samco hoses and braided oil/coolant lines etc):
self levelling suspension pump to be replaced with blanking plate:
rad and oil cooler to be replaced with a bigger unit inc' nice shiney braided lines:
bit of bling to keep me motivated....4th wheel is on its way I promise:
and for all those doubters, my last engine project.....Esprit Sport 350 V8
messing around with the inlet manifold, throttle and injection system in place seemed pointless...so...out:
much easier to work on now
will all look spanking when it goes back in:
harness and other bits tagged and out of the way:
complete exhaust removed:
Apart from fan, prop shaft and a couple of odds and sods, it's ready for out:
So, a couple of hours saw the engine out.
Pulled it at about 45 degrees to allow the sump to clear the front rail and the gearbox to swing under the bulkhead, then had to manhandle the tail of the 'box over the rail....job done.......sorry I had my hands full so didn't take any pictures of that bit.
engine out ready for 'box removal
lots of cleaning and tidying to do in the engine bay, I'm looking forward to that
propping the engine to provide clearance for gearbox removal
the old man getting stuck in
minor signs of wear on the springs suggest this clutch was ready for changing
flywheel all good
on the stand ready for work
off with the rear sub frame and a few bits to make it light:
aaaaaand.....up and over we go!!!
underside isn't too bad at all:
bit of dicky repair work by a.n. other:
engine still ready for strip down:
the proud father:
So, over the next few weeks I'm hoping to strip down the reast of the car (brake lines etc) and strip all the sealant from the u/s, I can then start with the welding.
I'll keep the thread posted on progress, comments and more importantly advice more than welcome...........
This is a standard 190e 2.3 16v, some refer to them as Cosworths due to the Cosworth cylinder head, I'm not sure about the credibility of claiming it to be a 'Cozzy' on account of an engine part, but there's no mistaking 185bhp from a 4 cyl 2.3 back in 1986 was pretty impressive.
Anyway, the intention being a stripped out track car loosely based on the DTM (deutsche tourenwagen meisterschaft) race car of the 80's
So, a full strip down and shell repair ready to receive:
- stock but fully rebuilt engine
- electronic fuel injection to replace the Bosch K Jet system
- 6 pot brabus brakes to the front and 4 pot brabus to the rear, larger grooved and vented disks obviously
- 17" ronal wheels with 888's or proxy T1r's
- complete new h&r cup suspension (ditch the self levelling rubish)
- roll cage and carbon race seats
- harnesses
- all salvaged parts blasted/dipped/cleaned, re-finished and re-bushed
- full geo' alignment and corner weighting
hoping to have it around 1000kg's and 190-200bhp but most importantly, handling well and reliable.
here's where it all began:
Collection from Perth, Scotland
back home, on stands and wheels off ready for assessment:
idea of the work ahead:
front of the car stripped:
left light well:
right light well:
inner wing:
cill at drivers door:
cill at rear arch:
below rear window:
inside boot to rear arch:
interior out and not looking too shabby
prod around underneath and and floor pan is in good shape
now call me insane, but this doesn't seem too bad to me
rear of the car and light wells not too bad
spare wheel well surface rusty but nothing poked through
So, front suspension and steering stripped and duly binned
Ground away some rust to find that the wishbone mounts are good, both sides
But the N/S spring top mount needs some work
Fortunately the shock top mounts are good, only surface rust
Corner of the inner wing not as bad as the other side
And amazingly the N/S cill is solid!
Rear of the car on the under side basically good
Nothing salvagable, all ordered
Things like wishbones I've got from a breaker and they were in very good condition, but I've still sent them off to have the bushes and ball joints popped, powder coated and re-bushed.
With the inner arches treated and sealed, new suspension, brakes and refurbed other bits, it should look quite nice down there at some point hopefully soon.
Cleaned up arches
It'll get a new clutch anyway, so that should be an easy job, I've also got a short shift kit for it.
next job was to remove the radiator and oil cooler:
the engine and bay would deffo benefit from a full clean and tidy up to make it look trick (samco hoses and braided oil/coolant lines etc):
self levelling suspension pump to be replaced with blanking plate:
rad and oil cooler to be replaced with a bigger unit inc' nice shiney braided lines:
bit of bling to keep me motivated....4th wheel is on its way I promise:
and for all those doubters, my last engine project.....Esprit Sport 350 V8
messing around with the inlet manifold, throttle and injection system in place seemed pointless...so...out:
much easier to work on now
will all look spanking when it goes back in:
harness and other bits tagged and out of the way:
complete exhaust removed:
Apart from fan, prop shaft and a couple of odds and sods, it's ready for out:
So, a couple of hours saw the engine out.
Pulled it at about 45 degrees to allow the sump to clear the front rail and the gearbox to swing under the bulkhead, then had to manhandle the tail of the 'box over the rail....job done.......sorry I had my hands full so didn't take any pictures of that bit.
engine out ready for 'box removal
lots of cleaning and tidying to do in the engine bay, I'm looking forward to that
propping the engine to provide clearance for gearbox removal
the old man getting stuck in
minor signs of wear on the springs suggest this clutch was ready for changing
flywheel all good
on the stand ready for work
off with the rear sub frame and a few bits to make it light:
aaaaaand.....up and over we go!!!
underside isn't too bad at all:
bit of dicky repair work by a.n. other:
engine still ready for strip down:
the proud father:
So, over the next few weeks I'm hoping to strip down the reast of the car (brake lines etc) and strip all the sealant from the u/s, I can then start with the welding.
I'll keep the thread posted on progress, comments and more importantly advice more than welcome...........