Wes-Spec 4x4 Sapphire Cosworth
21-05-2009, 10:43 PM
#81
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Here are some pics of the WRC breather fitted 
The top mount is temporarily held in place with a nut + bolt to put it in the same position as when the inlet manifold is fitted:
Note clearence to dipstick tube, this hasn't been modified in any way:
Front view:
The top mount is temporarily held in place with a nut + bolt to put it in the same position as when the inlet manifold is fitted:
Note clearence to dipstick tube, this hasn't been modified in any way:
Front view:
07-02-2010, 07:11 PM
#85
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Not much progress to report as I haven't been taking any pics as I go along since putting the engine back in, but I did take a video of what the aim dash does now Ive wired in the sequential shifter:
The sequential adapter for the gearbox came with it's own little display but it meant finding somewhere to hide the electronics for it so decided to wire the sensor straight into the dash, I was quite impressed it worked on my first attempt!
The sequential adapter for the gearbox came with it's own little display but it meant finding somewhere to hide the electronics for it so decided to wire the sensor straight into the dash, I was quite impressed it worked on my first attempt!
14-02-2010, 08:08 PM
#91
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Not much to report this week, waiting on a couple of parts before I can bolt the front suspension back on properly and put it back onto 4 wheels for the 1st time in years 
I've been under the car fitting new oil lines and coolers for the centre diff and gearbox today, no pics as it was so cold I couldn't feel my hands or toes!
Alos my new adjustable TCA's arrived this week via Martoon, I decided to replace the Zoo ones I had as they had started to ovalise in the ball joint area (under the rubber boot), and what I hadn't noticed until last year was they had not used the nearly new Ford TCA's that the car had when it went in there with to convert, they had used cheap crap ones with tiny ball joints (about 8mm smaller than standard!!!) The pics will show what i mean, note the diammeter of the circles at the bottom:
Left to Right: Reyland supplied, Standard, Zoo.
The adjustable hardware on the new ones is also alot beefier:
I've been under the car fitting new oil lines and coolers for the centre diff and gearbox today, no pics as it was so cold I couldn't feel my hands or toes!Alos my new adjustable TCA's arrived this week via Martoon, I decided to replace the Zoo ones I had as they had started to ovalise in the ball joint area (under the rubber boot), and what I hadn't noticed until last year was they had not used the nearly new Ford TCA's that the car had when it went in there with to convert, they had used cheap crap ones with tiny ball joints (about 8mm smaller than standard!!!) The pics will show what i mean, note the diammeter of the circles at the bottom:
Left to Right: Reyland supplied, Standard, Zoo.
The adjustable hardware on the new ones is also alot beefier:
15-02-2010, 10:05 PM
#94
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I had compression struts along time ago and they bent after a while so I put an Escort ARB on the front, I'm going to stick with this setup for the time being
30-03-2010, 03:31 PM
#95
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Thread Starter
I've made quite alot of progress the past few weeks but haven't taken many pictures, Gearbox and Centre diff coolers now mounted and all new lines run to them with fluids topped up, changed front + rear diff fluids with Mobilube SHC, fitted new TCA's and ARB etc.
I've also spend abit of time sorting out the cam cover, header tank + swirl pot. Decided to paint them with wrinkle paint to make them more durable and less maintenance, swirl pot came out OK on 1st attempt but header tank messed up 1st time so had it sand blasted and got it OK on the 2nd go, cam cover I had machined to remove the lettering and then sand blasted to roughen the machined surface, then prayed as I painted it ha-ha! I think it came out alright, it is darker in the flesh:
Will be attacking it over the next week so hopefully will have started it and have it rolling by then
I've also spend abit of time sorting out the cam cover, header tank + swirl pot. Decided to paint them with wrinkle paint to make them more durable and less maintenance, swirl pot came out OK on 1st attempt but header tank messed up 1st time so had it sand blasted and got it OK on the 2nd go, cam cover I had machined to remove the lettering and then sand blasted to roughen the machined surface, then prayed as I painted it ha-ha! I think it came out alright, it is darker in the flesh:
Will be attacking it over the next week so hopefully will have started it and have it rolling by then
05-04-2010, 07:54 PM
#98
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Been abit ill for the past week, some of it my own fault for drinking too much over the weekend but still managed to do some work on it today, here are some pics of the engine bay, still got abit of work to do in there like make the heatshield etc but it's coming together nicely now:
06-04-2010, 11:01 PM
#103
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Cheers fellas
Yes the gussetts were put in by the cage builder to add strength to the inner wings / struts in combinaton with the cage, no need for strut brace now. I think they used to put another inner wing ontop of the original and weld it in (to double skin it basically) to do the same thing.
Yes the gussetts were put in by the cage builder to add strength to the inner wings / struts in combinaton with the cage, no need for strut brace now. I think they used to put another inner wing ontop of the original and weld it in (to double skin it basically) to do the same thing.
25-04-2010, 07:41 AM
#106
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It's ALIVE! Well quite a lot has been done on it in the last few weeks and I started it for the 1st time in 5 years last weekend! And it started on the 1st attempt I was really impressed with myself (and the map supplied in the ECU) on that one considering i've built the engine and rewired the entire car from scratch myself!
There were a few technical issues found once it was running however, the alternator light didn't come on and it wasn't charging the battery, I was panicking abit there as i thought i might have wired it up wrong but abit of testing found I had wired it correctly and it was a duff alternator so I splashed out on a 145 amp Brise jobbie with twin internal fans. I now get 14.5 volts at idle I also have a little oil leak from the turbo oil return so will change the new gasket for another new gasket 
Anyway here is a vid of it running yesterday (20mb video), please bear in mind this is a "work in progress" and still requires tweeking.
I was really impressed with myself (and the map supplied in the ECU) on that one considering i've built the engine and rewired the entire car from scratch myself!There were a few technical issues found once it was running however, the alternator light didn't come on and it wasn't charging the battery, I was panicking abit there as i thought i might have wired it up wrong but abit of testing found I had wired it correctly and it was a duff alternator so I splashed out on a 145 amp Brise jobbie with twin internal fans. I now get 14.5 volts at idle
I also have a little oil leak from the turbo oil return so will change the new gasket for another new gasket Anyway here is a vid of it running yesterday (20mb video), please bear in mind this is a "work in progress" and still requires tweeking.
26-04-2010, 11:14 AM
#108
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27-06-2010, 10:59 PM
#115
I've found that life I needed.. It's HERE!!
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Well I finally got it to the point were it could be driven a few weeks ago, only to have a few technical issues
I had originally fitted an electro/hydro power steering pump out of a Renault Clio Diesel that I got out of a scrappy for Ł80 about 3 years ago, it worked at the time but decided to die (and produce alot of smoke!) a few weeks ago, and even when it did work it was noisy as I had mounted it in the passenger foot well, I already have 3 fuel pumps in the boot so that just made it abit too loud and the fact that they are Ł400 new to replace (or Ł185 recon) put an end to that so I decided to revert back to the mechanical power steering setup but of course I couldnt go back to the sierra setup now so opted for the small turbo escort setup which is alot neater but was a pain in the RS to fit in my car (of course!):
I had to rework the heatshield I made for the new alternator abit too but it was easy enough:
There were various other little problems but Ive nearly fixed them all now, I have to replace the lift pump as its buggered and getting red hot, luck y Ive just put loads of petrol in the tank then But it doesnt stop the car from running so today I drove it to the top of the road and back again under its own power (and brakes) for the 1st time in 5 years
I can see the light at the end of the tunnel now
And heres a few random pictures I took of the engine bay today:
I had originally fitted an electro/hydro power steering pump out of a Renault Clio Diesel that I got out of a scrappy for Ł80 about 3 years ago, it worked at the time but decided to die (and produce alot of smoke!) a few weeks ago, and even when it did work it was noisy as I had mounted it in the passenger foot well, I already have 3 fuel pumps in the boot so that just made it abit too loud and the fact that they are Ł400 new to replace (or Ł185 recon) put an end to that so I decided to revert back to the mechanical power steering setup but of course I couldnt go back to the sierra setup now so opted for the small turbo escort setup which is alot neater but was a pain in the RS to fit in my car (of course!):
I had to rework the heatshield I made for the new alternator abit too but it was easy enough:
There were various other little problems but Ive nearly fixed them all now, I have to replace the lift pump as its buggered and getting red hot, luck y Ive just put loads of petrol in the tank then
But it doesnt stop the car from running so today I drove it to the top of the road and back again under its own power (and brakes) for the 1st time in 5 years I can see the light at the end of the tunnel now
And heres a few random pictures I took of the engine bay today:
28-07-2010, 10:41 PM
#117
I've found that life I needed.. It's HERE!!
Thread Starter
Here are a few up to date pics of the car, plan is to get it Taxed + MOT'd in a couple of weeks when i'm back from Holiday then start gettig some miles under it's belt
