White Sapphire Cosworth Build... From Scratch!!! (Update... 24/02/10)

Simmo · 06-09-2007, 07:13 PM

Right, here we go... the start of my thread rebuilding AlexD's old white 2wd Sapphire Cosworth.

I collected it on 24/08/07 but hadn't had a chance to post anything due to work commitments etc.

This is what i'm starting with...

A big thanks to Alex for all your help and obvious hard work in the time you had it!!!

Updates as and when progress is made...

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Munch · 06-09-2007, 07:28 PM

thats a tidy shell you got there

Nash · 06-09-2007, 08:42 PM

Quote:

Originally Posted by Sidewayz

thats a tidy shell you got there

I will second that

You going to be making it 2wd or 4x4?

Simmo · 06-09-2007, 09:32 PM

Cheers for the comments guys... it's very clean underneath.. no previous welding etc...

It's a 1990 2wd and that's the way it will stay... just built back up by myself to my own spec!

Richie. · 06-09-2007, 09:38 PM

Nice project there

CharlieSaff · 07-09-2007, 05:50 AM

Yeah good luck with this Paul will keep an eye on it

KSA-Cossie · 07-09-2007, 06:12 AM

Very good base to start from m8.

fezzajsy · 07-09-2007, 08:15 PM

shell looks very clean

gaz3678 · 17-10-2007, 06:55 AM

Dude where's the update's?? Gonna show us what you've done in the last 2 months? Dying to see mate,

Ads

Simmo · 30-10-2007, 09:56 PM

Right, a small update... progress has been pretty slow due to the house being on the market, work and all the other usual excuses!!!

The underneath of the shell was very tidy and straight so wanted to keep it this way by going down the Waxoyl route. I know for the best looking results it should be painted white but i'm more of a functional/practical fan (plus i hate trying to keep stuff clean!).

So a few layers of the black stuff will be used and if a job's worth doing its worth doing properly so that means the whole underside is going to be done, inner arches as well.

First all the rolling gear and brake/fuel lines were removed, cleaned up and painted... (only a couple of pics)

Then the underside could be cleaned more thoroughly...

Finished the 2nd Waxoyl coat today, doing another tomorrow, then the pics will follow... pretty pleased with the results so far though!

Also bought a few bits...

...a bit premature i know but i managed to pick up a good set of leather including doorcards (thanks Amy for letting me turn the spare room into a cossie parts store! x

)... I sold her sun-bed the other day for a bit of extra room!

...

A big THANKS to Kev Sharp for all the help with the bits from
dovboy's big spec Sapphire; a top guy

From this i had bonnet (damaged in transit!), bootlid, doors, sideskirts, rear lights, morrettes plus more!

Although the doors/bootlid are all on and open/close ok they still need a bit of fine-tuning to get panel gaps spot-on but it'll be going in for fresh paint at the end anyway so for now they'll do nicely! (Although paint match looks pretty good at the mo but that's not in natural light!

)

I got the morrettes but i can't decide what look to go for... either subtle with standard headlights and orange indicators (which is 'in' at the moment!) or the more aggressive look?! Either way i can always sell them again!

That's it for now...

BRAMMER · 30-10-2007, 11:02 PM

Looking good

R5COS · 30-10-2007, 11:19 PM

looking good m8 its always nice to start with a good base when you taking something like this on makes life kinda easy.. keep it up

gaz3678 · 31-10-2007, 08:22 AM

Not sure if it's due to Cosworth withdrawl symptoms, but is that a Rouse spoiler? It just doesn't look 'right' to me, looks good though!
Ads

coswurv · 31-10-2007, 08:23 AM

looking good, nice to see another one saved from certain death !

Simmo · 31-10-2007, 08:29 AM

Thanks guys...

Ad... yes its delocked with a genuine Rouse spoiler!

MorryRS · 31-10-2007, 08:34 AM

Looks nice and clean

Look foward to see the progress

AlexD · 31-10-2007, 08:52 AM

Excellent !! She will be back to her former Glory

I always wanted to do the underside, never had the time

Keep up the good work mate

Al..

Simmo · 31-10-2007, 09:21 AM

Quote:

Originally Posted by AlexD

Excellent !! She will be back to her former Glory

Well looking at some past pics Alex if she looks half as good i'll be happy!

Quote:

Originally Posted by AlexD

I always wanted to do the underside, never had the time

To be fair it looked pretty good as it was... you did a good job of keeping it clean!

EssexMikeSi · 31-10-2007, 11:24 PM

shell looks really tidy mate, well done on finding a rouse spoiler for it. Morettes would look smart on there i reckon, if colour coded

Best of luck with it, i'll be checking for updates

Kevin Sharp · 16-11-2007, 07:59 PM

Looking good paul

any more progress? sorry i didnt reply to your email you sent a couple of weeks ago, i only just found it tonight, must have opened it when i was pissed and thought oh i,ll reply later

182_blue · 16-11-2007, 08:04 PM

keep um coming

Simmo · 19-11-2007, 09:52 PM

Another small update... at last i've finished Waxoyling the underside, after 4 coats!!! I never wanna do that again!...

...and i've still got a couple of small bits to do like the sides inside boot, box sections under rear seat etc. Anyway here's some pics (sorry about quality, if i took them with flash it reflected like mad or without it looks grainy!

)

TCA's and Lower Arm's ready to go on with poly bushes and Mr Rainbird's shims respectively!

Got new drop-links for the rear anti-roll bar from Ford for £8.50 each including bushes... bargain!

So now everything can start going back on the car but need to get some new brake/fuel pipe clips for underneath first, oh and the Koni/Ahmed kit is on its way from Mike Rainbird... watch this space!

gaz3678 · 20-11-2007, 12:19 PM

Looks very good mate, I've seen cars with worse outsides than your underside! Just a thought- what about white stonechip paint over the lot? 2 birds & one stone so to speak?
Top Ads Tip- white hammerite is a dead match for Diamond white

good for towing eyes etc.

Anyways thought you decided on the Gaz coilovers?

CosKev3 · 20-11-2007, 01:20 PM

Looking good

Shell looks mint

I would have done the underside white though after cleaning it up like you did,each to there own though

Pete 3dr · 20-11-2007, 01:24 PM

This will be lovely when complete...

Agree with Kev..WHITE underside...

StickerPaul · 20-11-2007, 01:35 PM

Stunning work mate....

Ignore the 2 bufty's above.....it looks a lot better black

CosKev3 · 20-11-2007, 01:47 PM

Quote:

Originally Posted by StickerPaul

Stunning work mate....

Ignore the 2 bufty's above.....it looks a lot better black

Just cause your too tired to do yours!!!!!!!!!!

StickerPaul · 20-11-2007, 01:50 PM

Hello stranger

hows tricks!

Your right Kev, i can't be arsed to do mine

fezzajsy · 20-11-2007, 02:47 PM

Quote:

Originally Posted by staffi

This will be lovely when complete...

Agree with Kev..WHITE underside...

totally right

Pete 3dr · 20-11-2007, 03:04 PM

Quote:

Originally Posted by StickerPaul

Hello stranger

hows tricks!

Your right Kev, i can't be arsed to do mine

Think it's that winter feeling Paul, no shows etc..

It'll be back though mate, i know you..

Simmo · 20-11-2007, 04:21 PM

Cheers guys!

Well the thing i'm worried about is it not staying clean if its white, not that it'll be out in bad weather, i just wanted to get a job done well and forget about it... i'm not bothered about looks too much...

...but i am easily pursuaded!

But to be honest it looks much better in the flesh, pretty good matt black against the white body... but you lot have got me thinking now!... hhhhhmmmmm...

Ad Yeah was gonna go for the coilovers but have been advised otherwise if i'm getting 'cheap' ones!

ram · 20-11-2007, 05:55 PM

looking good

CosKev3 · 20-11-2007, 09:49 PM

Some of mine to help you decide pal.......

You know it makes sense........

Simmo · 20-11-2007, 10:08 PM

CosKev3

That looks stunning!

But i think i'm gonna stick with the black finish, i'm not too bothered about looks.

...

...plus i'm pretty sure Waxoyl can't be painted on

CosKev3 · 20-11-2007, 10:13 PM

Thanks

Did the front to match too

Simmo · 20-11-2007, 10:26 PM

That's top draw Kev!

I have so much respect for guys producing concours-standard cars, the attention to detail is amazing, but it's just not my scene... i've got a big enough task as it is! I'll just settle for 'clean' and 'tidy'

No Brakes · 20-11-2007, 10:55 PM

keep going fella. it looks the bollox mate.

StickerPaul · 21-11-2007, 12:55 PM

Kev = BUFTY

Looking good as ever mate

is the engine bay painted now???

olek · 21-11-2007, 02:04 PM

looks good!

white ones are the best!

CosKev3 · 21-11-2007, 10:18 PM

Quote:

Originally Posted by StickerPaul

Kev = BUFTY

Looking good as ever mate

is the engine bay painted now???

Not yet,FFS only been off the road for 12 months,can't rush these things!!!!

Needs new battery tray before getting eng bay painted

Haven't touched it for months

was thinking of getting rid

Viewed a few Mk2 RS Escorts,but back on track with the Saph now

06-09-2007, 07:28 PM	#2
Munch Mr. Sparkle! Trader Score: (0) Join Date: Nov 2005 Location: Wiltshire - swindon Posts: 12,097	thats a tidy shell you got there __________________ CHEERS, LEE Onslow Loves COD! Arguing on the internet is like racing in an impreza, even if you win, you're still a twat.

06-09-2007, 09:32 PM	#4
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	Cheers for the comments guys... it's very clean underneath.. no previous welding etc... It's a 1990 2wd and that's the way it will stay... just built back up by myself to my own spec! __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

06-09-2007, 09:38 PM	#5
Richie. aka Turbosailorboy Trader Score: (3) Join Date: Apr 2005 Location: Under the water.... .......in a nuclear submarine Posts: 4,792	Nice project there __________________ www.adrenalinerace.com www.reyland.co.uk www.randbmotorsport.co.uk 909sport ~ For all your braking and Suspention needs ~ Contact NUTs RuS for any questions or enquirys.

07-09-2007, 05:50 AM	#6
CharlieSaff I've found that life I needed.. It's HERE!! Trader Score: (0) Join Date: May 2004 Location: West Sussex Posts: 1,059	Yeah good luck with this Paul will keep an eye on it __________________ T34.63//350BHP//350FT/LB//AP 4 Pot's//1.9BAR Spike//6° ADR Rear Beam My Rear End Restoration West Sussex RS Owners Club

07-09-2007, 06:12 AM	#7
KSA-Cossie 15K+ Super Poster!! Trader Score: (2) Join Date: May 2004 Location: Shutting down jap crap Posts: 19,475	Very good base to start from m8. __________________ cheeRS kev T34.63,siemens blacks,500 intercooler,stage 3,MSD closed loop & wasted spark,18" MO's,362mm discs,AP 6 pots,ALS & LC. Motorsport Developments 01253 508400

07-09-2007, 08:15 PM	#8
fezzajsy PassionFord Post Whore!! Trader Score: (4) Join Date: Nov 2004 Location: jeRSey..isles Posts: 9,795	shell looks very clean __________________ http://passionford.com/forum/restora...y-tidy-up.html

17-10-2007, 06:55 AM	#9
gaz3678 Wahay!! I've lost my Virginity!! Trader Score: (0) Join Date: Jan 2005 Location: Surrey/ Sussex Posts: 59	Where's the pic's? Dude where's the update's?? Gonna show us what you've done in the last 2 months? Dying to see mate, Ads __________________ Cosworth owners guide: 1) Learn how to gobble your bank manager.

30-10-2007, 09:56 PM	#10
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	Right, a small update... progress has been pretty slow due to the house being on the market, work and all the other usual excuses!!! The underneath of the shell was very tidy and straight so wanted to keep it this way by going down the Waxoyl route. I know for the best looking results it should be painted white but i'm more of a functional/practical fan (plus i hate trying to keep stuff clean!). So a few layers of the black stuff will be used and if a job's worth doing its worth doing properly so that means the whole underside is going to be done, inner arches as well. First all the rolling gear and brake/fuel lines were removed, cleaned up and painted... (only a couple of pics) Then the underside could be cleaned more thoroughly... Finished the 2nd Waxoyl coat today, doing another tomorrow, then the pics will follow... pretty pleased with the results so far though! Also bought a few bits... ...a bit premature i know but i managed to pick up a good set of leather including doorcards (thanks Amy for letting me turn the spare room into a cossie parts store! x )... I sold her sun-bed the other day for a bit of extra room! ... A big THANKS to Kev Sharp for all the help with the bits from dovboy's big spec Sapphire; a top guy From this i had bonnet (damaged in transit!), bootlid, doors, sideskirts, rear lights, morrettes plus more! Although the doors/bootlid are all on and open/close ok they still need a bit of fine-tuning to get panel gaps spot-on but it'll be going in for fresh paint at the end anyway so for now they'll do nicely! (Although paint match looks pretty good at the mo but that's not in natural light! ) I got the morrettes but i can't decide what look to go for... either subtle with standard headlights and orange indicators (which is 'in' at the moment!) or the more aggressive look?! Either way i can always sell them again! That's it for now... __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

30-10-2007, 11:02 PM	#11
BRAMMER Passionford.com Trader Score: (4) Join Date: Dec 2004 Location: North West Posts: 3,906	Looking good __________________ Cosworth Photoshoot

30-10-2007, 11:19 PM	#12
R5COS I've found that life I needed.. It's HERE!! Trader Score: (0) Join Date: Apr 2007 Location: IRELAND Posts: 1,053	looking good m8 its always nice to start with a good base when you taking something like this on makes life kinda easy.. keep it up __________________ view my escort cosworth underside restro here http://www.passionford.com/forum/viewtopic.php?t=292447

31-10-2007, 08:22 AM	#13
gaz3678 Wahay!! I've lost my Virginity!! Trader Score: (0) Join Date: Jan 2005 Location: Surrey/ Sussex Posts: 59	Spoiler Not sure if it's due to Cosworth withdrawl symptoms, but is that a Rouse spoiler? It just doesn't look 'right' to me, looks good though! Ads __________________ Cosworth owners guide: 1) Learn how to gobble your bank manager.

31-10-2007, 08:23 AM	#14
coswurv Advanced PassionFord User Trader Score: (6) Join Date: Dec 2006 Location: oxford Posts: 1,908	looking good, nice to see another one saved from certain death ! __________________

31-10-2007, 08:29 AM	#15
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	Thanks guys... Ad... yes its delocked with a genuine Rouse spoiler! __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

31-10-2007, 08:34 AM	#16
MorryRS Regular Contributor Trader Score: (0) Join Date: May 2007 Location: Ardrossan Posts: 258	Looks nice and clean Look foward to see the progress __________________ White S2 Turbo R.I.P Miami Blue S2 Turbo Still here

31-10-2007, 08:52 AM	#17
AlexD Post Miester ! Trader Score: (1) Join Date: May 2003 Location: Brizzol! oo'er! Posts: 4,555	Excellent !! She will be back to her former Glory I always wanted to do the underside, never had the time Keep up the good work mate Al.. __________________ ESCOS RESTO =>http://www.passionford.com/forum/viewtopic.php?t=295014

31-10-2007, 11:24 PM	#19
EssexMikeSi PassionFord Post Troll Trader Score: (0) Join Date: Jun 2003 Location: Maldon, Essex! Posts: 3,295	shell looks really tidy mate, well done on finding a rouse spoiler for it. Morettes would look smart on there i reckon, if colour coded Best of luck with it, i'll be checking for updates

16-11-2007, 07:59 PM	#20
Kevin Sharp PassionFord Post Whore!! Trader Score: (2) Join Date: May 2003 Location: Glenrothes, Fife Posts: 5,332	Looking good paul any more progress? sorry i didnt reply to your email you sent a couple of weeks ago, i only just found it tonight, must have opened it when i was pissed and thought oh i,ll reply later __________________ 500+BHP RWD ESCORT COSWORTH WITH TREMEC TKO + 9" DIFF

16-11-2007, 08:04 PM	#21
182_blue Wahay!! I've lost my Virginity!! Trader Score: (0) Join Date: Apr 2006 Location: Nottingham Posts: 61	keep um coming __________________

19-11-2007, 09:52 PM	#22
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	White Sapphire Cosworth Rebuild... From Scratch!! (19/11/07) Another small update... at last i've finished Waxoyling the underside, after 4 coats!!! I never wanna do that again!... ...and i've still got a couple of small bits to do like the sides inside boot, box sections under rear seat etc. Anyway here's some pics (sorry about quality, if i took them with flash it reflected like mad or without it looks grainy! ) TCA's and Lower Arm's ready to go on with poly bushes and Mr Rainbird's shims respectively! Got new drop-links for the rear anti-roll bar from Ford for £8.50 each including bushes... bargain! So now everything can start going back on the car but need to get some new brake/fuel pipe clips for underneath first, oh and the Koni/Ahmed kit is on its way from Mike Rainbird... watch this space! __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

20-11-2007, 12:19 PM	#23
gaz3678 Wahay!! I've lost my Virginity!! Trader Score: (0) Join Date: Jan 2005 Location: Surrey/ Sussex Posts: 59	Suspension Looks very good mate, I've seen cars with worse outsides than your underside! Just a thought- what about white stonechip paint over the lot? 2 birds & one stone so to speak? Top Ads Tip- white hammerite is a dead match for Diamond white good for towing eyes etc. Anyways thought you decided on the Gaz coilovers? __________________ Cosworth owners guide: 1) Learn how to gobble your bank manager.

20-11-2007, 01:20 PM	#24
CosKev3 PassionFord Post Troll Trader Score: (0) Join Date: Apr 2004 Location: Shropshire. Posts: 2,991	Looking good Shell looks mint I would have done the underside white though after cleaning it up like you did,each to there own though __________________ . . . Saph gone,but not forgotten. My car interests have EVOlved............. You may PREFER your Cosworth,but not a sniff they are BETTER cars than Evos sorry................. My 309 Gti re-shell/resto thread: http://www.309ownersclub.com/Communi...hp?f=30&t=3552

20-11-2007, 01:24 PM	#25
Pete 3dr NMS GUNSHIP AND LOVING IT Trader Score: (0) Join Date: Nov 2005 Location: Coventry Posts: 13,308	This will be lovely when complete... Agree with Kev..WHITE underside... __________________

20-11-2007, 01:35 PM	#26
StickerPaul 20K+ Super Poster. Trader Score: (2) Join Date: Apr 2004 Location: Liverpool Posts: 20,093	Stunning work mate.... Ignore the 2 bufty's above.....it looks a lot better black __________________ www.richardburnsfoundation.com

20-11-2007, 01:50 PM	#28
StickerPaul 20K+ Super Poster. Trader Score: (2) Join Date: Apr 2004 Location: Liverpool Posts: 20,093	Hello stranger hows tricks! Your right Kev, i can't be arsed to do mine __________________ www.richardburnsfoundation.com

20-11-2007, 04:21 PM	#31
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	Cheers guys! Well the thing i'm worried about is it not staying clean if its white, not that it'll be out in bad weather, i just wanted to get a job done well and forget about it... i'm not bothered about looks too much... ...but i am easily pursuaded! But to be honest it looks much better in the flesh, pretty good matt black against the white body... but you lot have got me thinking now!... hhhhhmmmmm... Ad Yeah was gonna go for the coilovers but have been advised otherwise if i'm getting 'cheap' ones! __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

20-11-2007, 05:55 PM	#32
ram Has a large member Trader Score: (0) Join Date: Jun 2005 Location: oxFORDshire Posts: 2,232	looking good __________________

20-11-2007, 09:49 PM	#33
CosKev3 PassionFord Post Troll Trader Score: (0) Join Date: Apr 2004 Location: Shropshire. Posts: 2,991	Some of mine to help you decide pal....... You know it makes sense........ __________________ . . . Saph gone,but not forgotten. My car interests have EVOlved............. You may PREFER your Cosworth,but not a sniff they are BETTER cars than Evos sorry................. My 309 Gti re-shell/resto thread: http://www.309ownersclub.com/Communi...hp?f=30&t=3552

20-11-2007, 10:08 PM	#34
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	CosKev3 That looks stunning! But i think i'm gonna stick with the black finish, i'm not too bothered about looks. ... ...plus i'm pretty sure Waxoyl can't be painted on __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

20-11-2007, 10:13 PM	#35
CosKev3 PassionFord Post Troll Trader Score: (0) Join Date: Apr 2004 Location: Shropshire. Posts: 2,991	Thanks Did the front to match too __________________ . . . Saph gone,but not forgotten. My car interests have EVOlved............. You may PREFER your Cosworth,but not a sniff they are BETTER cars than Evos sorry................. My 309 Gti re-shell/resto thread: http://www.309ownersclub.com/Communi...hp?f=30&t=3552

20-11-2007, 10:26 PM	#36
Simmo I've found that life I needed.. It's HERE!! Trader Score: (8) Join Date: Dec 2004 Location: West Sussex Posts: 1,084	That's top draw Kev! I have so much respect for guys producing concours-standard cars, the attention to detail is amazing, but it's just not my scene... i've got a big enough task as it is! I'll just settle for 'clean' and 'tidy' __________________ Sapphire Cosworth Build... From Scratch!!!... MAD built, Vi-PEC managed... coming soon! West Sussex RS Owners Club

20-11-2007, 10:55 PM	#37
No Brakes Virgin Trader Score: (0) Join Date: Nov 2007 Posts: 1	keep going fella. it looks the bollox mate.

21-11-2007, 12:55 PM	#38
StickerPaul 20K+ Super Poster. Trader Score: (2) Join Date: Apr 2004 Location: Liverpool Posts: 20,093	Kev = BUFTY Looking good as ever mate is the engine bay painted now??? __________________ www.richardburnsfoundation.com

21-11-2007, 02:04 PM	#39
olek PassionFord Regular Trader Score: (0) Join Date: Jan 2005 Posts: 406	looks good! white ones are the best! __________________

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