jonny s2

iTrader: (12)

awesome pal,wheels look great weapon

johnnycos

Wow wow wow beast!!!!!

G950KDT

iTrader: (2)

thats properly nice mate! love it, i work with these now and then and have a 9 turbo and 5 turbo as well as my fords.... love that a lot!

stu21t

update,
as it now sits in my garage



the engines back out,
just for some cleaning, painting, rewiring.
i cant afford the stuff i wanted to do to it, due to some jobs cancelling on me in these shitty times.

i need a new waterpump as this ones packed up,
gunna get a std exhaust cam for it,
and some general tidying up.
so nothing exciting really.

not exactly much room to work,

whittyscossy

love it great work

andy escos

iTrader: (1)

Twins

iTrader: (18)

Bonkers

Bealo

Great project and i'm loving the standard look of the car, so much better now it's in white.

Can't wait to hear what it's like when you get your next set of mods done on it.

Brings back some fond memories of my Cossie powered GT Turbo many moons ago (nearly 15 years ago i think)

Good to see a fast 5 still on the road.

H7 CYA

iTrader: (3)

Thats mental awesome project

stu21t

bealo, did u have the 4x4 front engined green1?


tonights progress
engine totaly pulled out,
stripped loads of bits off the engine ready for cleaning/replacing

exhaust manifold off to be ceramic coated,
new waterpump,
new cam,






pics arent great cos taken off my phone and no flash.

marky_g

very cool mate

Bealo

Hi Stu

Yes i had the green one



Engine was no where near spec like yours but still did a 12.64 quarter, i would have loved a 450-500bhp lump in it but as you most probably know it went up in flames before we could get it properly finished.

Keep up the good work, cracking project mate.

stu21t

Yea m8, its a shame what happened to yours.

richbogle

pure sex man! luv cozys and luv r5s

stu21t

how it sits now.

just before the start of show seaon and the fun that comes with it and ive stripped it to the bones. lol

gearbox is out to be stripped, inspected, cleaned and repainted.
rear suspension is off for a cleanup
drive shafts need cv joints repacking and cleaning then paint


ive also done some more welding and paneling to the engine covers to seal it better, and done a load of cleaning/painting already.

hopefully i will get it back together soon, its booked to go on a stand at the rsoc central day in the middle of april so i better get a move on.

stu21t

all stripped


and 1 side all cleaned, painted and back together

stu21t

YEA BOY


engines back in.

after a full strip/rebuild/paint of the whole back end, inc. suspension, gearbox, engine its finally going back together

got a few more bits to do/order then its ready for the rollers again.

Zzz...Zzz

once again, awesome car - good to hear that it´s ready for action again!!

Stolton

WoW that looks the nuts mate !! :P

B16JUS

Awesome !

Chip

iTrader: (3)

Fantastic to see it back together again.

Love this car

CozzyKing

iTrader: (2)

Pukka, when you hoping to get it back on the road again?

stu21t

bad new peeps.
i got the car running on sunday
got it all back together on monday and went for a test drive on tuesday and it broke. lol

the cam cover gasket blew between the cams and spark plugs resulting in this


the oil ran out of the fronnt and back breather holes of the cam cover, and onto the cambelt and flywheel
meaning the whole fucking thing is now dripping in oil.

and then i lost all gears, it popped out of reverse while i was parking and then i couldnt get any gears.
im hoping the oil has caused the clutch to stick to the flywheel.


lets hope i can get it back together quick enough to get it mot'd on saturday for central day on sunday


other than that it was ok.

some more update pics:
under floor panel with vents for cooling


gearbox stripped

rebuilt

CozzyKing

iTrader: (2)

Shocking news mate, was hoping that you would be going to central day with this.
Hope it is easily fixed.

whittyscossy

Love it, bet it's great fun 2 drive.

stu21t

just came in for dinner so thought id do an update. lol


its all cleaned up,
i just used blue paper towel, and once it was as clean as i could get it i kept diluting it with degreaser till it was all gone.

jimbo, thanks for the offer but i have 1 on its way to me, should be here tomorow.


and






ive taken the clutch out already. lol
it looks quite clean but im gunna give it a clean up anyway and start to put it back together now.
i WILL make it on sunday. lol

whizzisat114

iTrader: (2)

Real shame after all your hard work. hope its back together id love to see this in the flesh at central day Good luck fella

stu21t

thats me done for the night
found a few problems.
the spline on the clutch centre plate was all burred up, so i had to file that down so it was all clean.

also i have a small metal adaptor that goes in the back of the crank where the pilot bearing goes, that adapts the renault un1 box to fit.
that had clearance probs so ive grinded that down for more room.

then sanded and cleaned the clutch cover, plate and flywheel.

now the clutch and box are all back in and bolted up.

tomorow i will get the hydraulics back in and bled, exhaust back on, and as long as the gasket turns up i will do the camcover and get it back out for another test drive.

CozzyKing

iTrader: (2)

Sounds like you will be at central day then hey?

stu21t

gaskets here, just about to fit it and pressure test the boost circuit then off on another test drive.
fingers crossed.
if all goes well its booked for an mot tomorow morning.

stu21t

update,
the reason i missed central day,
the clutch centre plate popped off the gearbox splines and rounded off the teeth on the plate, meaning i had a spinning engine and clutch but not gearbox.
im not too sure why this happened, i know my input shaft isnt aslong as a std cossie 1 but its been ok up until now,

so i have sent the paddle back to ap, via an authorised dealer (wont let me send it back direct)
and its getting a new spline/hub, hopefully with a spline that sticks out more into the box.

while its out ive taken my flywheel and cover plate to be skimmed, so when it comes back i will have a brand new clutch setup,
also getting a spare clutch master cylinder sleeved down from 28mm to 22mm, this should give me more throw at the release bearing, and a lighter pedal.
and for some reason i had 2 3mm plates between the engine and gearbox, to give the release bearing a bit of space to release, but i will be removing them to bring the box closer to the engine. this will help with disengagement and also give me more spline contact.
hopefully will get this all done in a couple of weeks ready to tax it at the start of may.

Acidburn

Looking good, any vids of it in action? bet you went thru rear tyres quite often.

stu21t

another bad update

after sending off the centre plate over a week ago.
ive now been told that ap wont repair it even tho when i rang and asked they told me they could
they want to sell me a new 1 @Ł200, and that could fail like this 1 did.
im now in talks with helix to see if they can make me a new 6 paddle centre plate with an extended spline.

also the man who was supposed to skim the flywheel and cover plate, hasnt, because he is very busy.

so for now i have got them back and put it all back together with the std centre plate i had in the car first time round, which is still in good condition.
i got as far as assembling everything and got it all back up and running, last night, but i need to bleed the clutch.
thats WAS gunna be tonights job.

but
at work today i was barrowing concrete from the street up the drive, round the back to concrete a patio slab.
and at 1 point the scaffold board i was on gave way, and i went over on my ankle, hurt like hell and is all swollen, problem is i had to finish the job, so i carried on working barrowing concrete for over an hour, then had to level the footings and clean/tidy up.
since i got home its been on ice, strapped up, i cant even put any weight on it.

so no clutch bleeding or test driving tonight. lol

Jim S

You need 5mm of clearance between the release bearing and the pressure plate (on a new pressure plate), this is to allow for the weakening of the pressure plate i.e. as it gets weaker it moves closer to the bearing.

Mine was too close and I ended up with a slipping clutch and thought I needed a new one and it turned out it was just set up too close.

With a central hydraulic slave cylinder it only moves back so just to clear the pressure plate so as not to give too much delay in the clutch working when you next press the pedal. Then as the pressure plate weakens the slave cylinder moves further back.

Do you have two plates, if so did you have them back to back, I had a similar problem with my input shaft and I turned one of my plates to face the same way (the one nearest the engine), had to skim the spline part down a touch to clear the other plate but it ensured full contact with the spline.

stu21t

i do remember that now when i 1st put it together i didnt have any gap between the release bearing and fingers, but this time round i do have a couple of mm clearance.
im getting a std sandwich plate to go inbetween and give me a few extra mms.

the stupid thing is its been like this for a couple of years, and the past 6 months with the ap paddle, and its been fine.

how did you get on with your gearbox?
i still wanna change mine but this will have to do for now.

Jim S

Got it all rebuilt but it is going up for sale as I have ordered a new one from Elite, due in the next few weeks. I've not refitted the old one since the rebuild as I want to sell it with zero hours since the build

Red16

Cool little car... any more photos of it externally since it was painted white?

Shame about the cam cover gasket, but at least its easily repaired.

stu21t

if only i could afford it jim.
do you do finance? lol

no red, no other pics.
will get some once its back out

stu21t

well update
i had today off cos of my fucked ankle,
so when i got bored of resting my foot, i went in the garage and bled the clutch and adjusted the pedal.
it worked
so i drove out of the garage and washed the car, but my foots not well enough to dare driving it properly.
lets hope tomorows ok, then i can test drive it and tax it.
i hope the clutch holds.

stu21t

YEA BABY
just got 1 of these


so now road legal(ish) lol for 6 months

also ordered an itg foam air filter and some hoses/ducting so will have an air filter for the 1st time ever. lol

have also done some more drilling of the rear bumper to let more heat out, its a bit less subtle but should heat getting the temp down.

still waiting on my new clutch slave to but have been told i might get it at the end of the week.

im off for a little drive as ive got tax. lol