White Sapphire Cosworth Build... From Scratch!!! (ABORTED!... most parts for sale!)

[CosKev3]

Nice work m8 When are you hoping to have this up and running????? Originally Posted by KSA-Cossie Awesome pal. Cheers,shame its sat in that cow shed since Nov 2006

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[nuttynil]

nice looks like a good one to start off with.........

[coswurv]

looking really smart mate, top work.

[wimble]

looks great
thinking of doing the same to mine now

[fezzajsy]

[Simmo]

Originally Posted by CosKev3

Nice work m8

When are you hoping to have this up and running?????

Well... I put a 2 year guestimate on it when I got it August '07 but I think it may be running by the end of the year!!!

Although I don't wanna rush anything and might just get the bodywork sorted in one hit which'll take a touch longer!!!

Thanks for the comments guys!

[AndyPen]

Theres a lot of work gone into these lads - nice jobs

[rostill2007]

love this project looks very nice and cant wait to see some more updates

[Simmo]

Cheers guys!!!

Should have an update shortly... haven't made any major progress as such, just acquired a few more bits, waiting for some more to arrive, stripping head down etc...

...made a pretty important decision on the body though; although it's pretty good i'm gonna have it all made 'perfect' while its still pretty bare...

[CosKev3]

Tidy.

Hows the front bumper now?????????

[Simmo]

Small update time... the house move has been abandoned due to what's going on with Northern Rock etc, a tad annoying cos I've been holding fire to a degree with the cossie but I suppose it means I can go mad now til it all calms down and the house goes back on the market!!!

Made a pretty important decision about the bodywork... I'm gonna go all out and get it done properly now while it's still fairly bare. Although the shell is very clean I want it perfect (and of course the doors, boot and bonnet won't be a perfect match anyway) and now is the time to do it I think. So it'll be trailered to the bodyshop soon...

I had an issue anyway with fitting the bumpers cos of broken brackets and rather than just bodging them on I want a more permanent fix, so they'll be coming back off and a local engineer is gonna make some new ones up hopefully...

First up, treated myself to a new 'proper' tool chest and roll cab set... much better knowing exactly where everything is!!!!



Popped the rod-ends on together with the steering wheel and lined up by eye so the front wheels are connected for when it needs to be moved...




Bought a few more bits... Mint Window Switch Surround



Mike Rainbird's uprated diff mount...



Side Repeaters...



O/S Rear Arch (one of the bits I want doing...)



New petrol tank (and gave it a spray up as well cos they tend to rust really quickly!!!) If anyone wants an old rusty one for nowt let me know before it goes to the tip...




Today I managed to fit the diff mount to the diff...



...and then fit the diff to the car (once i'd sorted out a stripped thread in the diff!!! )





And my head's off having a touch of corrosion sorted out and a re-face...

Hopefully the updates will be a bit more free flowing from now on...

[CosKev3]

Looking good m8.

Will your anti-roll bar clear the top bolt on your new diff mount when the weight is put on the wheels and the roll bar moves down?????

Only reason I ask is cause mine caught on the top bolt,had to grind the top bolts head down to stop it touching.

[James90RS]

Looks good Paul!

I have the same roll cab, I hope you got trade discount?

[hai07222]

Coming together nicely, good job

[dovboy]

looking good,is the fuel tank gen ford item? if not i would cut it open and weld in a collector near the fuel pump outlet.

surge on a non genuine tank is a bas****.trust me.

[fezzajsy]

looking good m8

[Simmo]

Kev... No it won't without minor mods, apparently it's only the 2wd Saffs that suffer with it, literally a matter of 2mm max which needs grinding off bolt head or ARB!!!

James... Cheers mate!!! Got it while it was on offer and worked out cheaper than using Akey's trade card anyway!!!

Dave... No it's not, although I have heard of the problem you mentioned... I've had a look inside the tank as much as I can and there is a round collector bowl the same as the standard part but metal, what's inside it I can't really see... If you look at the first fuel tank pic you can see the spot welds where it is mounted...

[James90RS]

Paul, you should still be able to use trade card it it on top of the deal

When I got my roll cab, it was originally Ł210, but then with a third off, then I saved Ł35 on top of that with the trade card!!

[Simmo]

Originally Posted by James90RS

Paul, you should still be able to use trade card it it on top of the deal

When I got my roll cab, it was originally Ł210, but then with a third off, then I saved Ł35 on top of that with the trade card!!

I was obviously told different then!!!... it probably depends which muppet you get served by!!!

I'll try it next time...

[James_RScos]

Looking good this mate, nice work.

[fezzajsy]

any updates m8?

[Simmo]

Update time... where has the last month gone?!!! Haven't done a great deal cos we're getting new windows and doors now we're not moving. But I am getting pretty excited about freshening up the bodywork!!!

First off, new stuff i've bought...

Had a cracking day at the central RSOC day at the Pod and bought a GroupA fuel pump and genuine tappets from Matt Lewis



A 10mm Plenum Spacer from RobS, should be getting inlet back soon so I can put it together...



And the 300mm rear disc kit from Tony (NUTS RuS)...



...which I quickly offered up to see what they looked like (still awaiting fronts and need to get 4x4 calipers!!!)



Got a few more bits painted inc exhaust manifold in black VHT which I think looks pretty good, although it'll probably be wrapped anyway!!!






All set for the bodyshop in a couple of weeks so have been stripping any trim that needs to come off in preparation, including bumper strips, door mouldings, handles, mirros, lock barrels, roof strips etc. Thankfully all the door mouldings came off pretty easily and in one piece cos they're very good!!!






All I need to do now is rig the windows so I can power them down to remove window rubbers...

Thanks for looking...

[COLEYST200]

Keep with it mate your done a nice job

[fezzajsy]

looking good man

[Simmo]

Originally Posted by COLEYST200

Keep with it mate your done a nice job

Cheers fella... just read the whole of your thread; awesome job you're doing, well done!!!

As you say it's the comments you get on here that keep you going so thanks to everyone who's posted so far!!!

[smerth54]

lovely saff you've got there mate keep up the good work

[Simmo]

This update's been in the pipeline for a while but I haven't had the time cos I've been away with the wife for our 1st anniversary in Scotland; what an amazing place, wanna move there now!!!

The Saff's now painted and to say i'm pleased with how it's come out is an understatement; it was pretty good and straight before but hopefully you'll see from the pics how much work was done... it looks so fresh and clean now, plus all the panel gaps and lines/swages are all now prefectly lined up and straight!!!

So a big thanks to Gav and Dom for their hardwork in not only getting the job done in no time through a night and hardly any sleep, but in doing a few little extras that came to light to make a proper job of it!!!

Anyway, enough of the waffle, here's the pics...

Before shot just before going on trailer (doesn't look any different to when I got it, apart from the addition of doors etc! )



All the odds and sods prepped and painted; I wanted everything matching so everything was done!















Dom in action... front arch needed a bit of work and had the mangled triangle bumper mount hole plate cut out and replaced with one from a new wing, and there was a bit of rot in the rear arch so it was cut out and again replaced with a piece from a new wing! (If anyone wants the front wing and rear arch minus those pieces let me know)





All 'worked' bits were masked up...





...and then primed...










The car masked and sealed ready for final paint...





The finished article... they're the only pics i've got at the mo and they don't really do it justice believe me!!!






Finally a couple of purchases...

Some pukka valve guides...



...and mint clocks and brand new bumper insert off Ben (cosjapeater)

[CharlieSaff]

Paul you must be well pleased with the paint job

Looks spot on mate

[Matt Baxter]

nice one mate looks very good not much left to do by the looks of it

[ital_cossie]

Very good job! keep up with updates and photos!

[CosKev3]

Looking very good m8.

Well worth getting a good paint job on that shell.

Shame my shell wasn't that good when the previous owner had all the body work done!!!!

[Mad Matt]

Mint car mate, congrats !

[dovboy]

Originally Posted by CosKev3

Looking very good m8.

Well worth getting a good paint job on that shell.

Shame my shell wasn't that good when the previous owner had all the body work done!!!!

same as mine,should have got hold of a better shell to paint

i did get a great deal on the paintwork,2wings replaced,28 little dents and marks filled(nothing big)flushed bootlid and spoiler fitted,whole car painted(inside boot+door checks) for Ł900!!

the shine on the rear quarter in this pic shows how good the paintjob was....




p.s simmo,i know the one to try and buy now if i ever want to get back into cosworths!!its looking great so far

[fezzajsy]

looking good

[hai07222]

Looking good, keep it up

[Simmo]

Thanks for all comments so far guys, it means a lot to me!!!

Originally Posted by Matt Baxter

nice one mate looks very good not much left to do by the looks of it

Cheers Matt, lol apart from putting the outside back together, putting the inside in, building the engine, rebuilding the gearbox, getting proper wheels etc etc

Originally Posted by dovboy

p.s simmo,i know the one to try and buy now if i ever want to get back into cosworths!!its looking great so far

Thanks Dave, and you know where quite a few of the bits have come from!!!

[CosKev3]

It will need a gen RS500 splitter on it though for sure when finishing off...................
PM for details m8.

[BIG TONY RS]

superb thread mate car is looking really good now cant wait to see it done

[Simmo]

Originally Posted by CosKev3

It will need a gen RS500 splitter on it though for sure when finishing off...................
PM for details m8.

Still in two minds which splitter to have Kev... I was just gonna stick with a Laguna one cos I wasn't too keen on the RS500 or Rouse ones but i'm slowly coming round to them now!!! (You have pm)

Originally Posted by BIG TONY RS

superb thread mate car is looking really good now cant wait to see it done

Thanks Tony... it means a lot to have these good comments from guys with awesome cossies themselves

[CosKev3]

Originally Posted by simmosaph

Still in two minds which splitter to have Kev... I was just gonna stick with a Laguna one cos I wasn't too keen on the RS500 or Rouse ones but i'm slowly coming round to them now!!! (You have pm)

It makes the Rouse ones look like snow ploughs m8!!!!!!!