2wd Cosworth rebuild-stood for 11 years! - SHE'S ALIVE
12-11-2007, 11:46 AM
#1
2wd Cosworth rebuild-stood for 11 years! - SHE'S ALIVE
I'm new to this forum so hello all.
I've recenty bought a G plate 2wd Cosworth that's been stood for 11 years with 54k on the clock. the story goes as follows......
i bought it from a mechanic friend who has millions of cars (1 in fact is a RS500 which has been in storage since 1990) - he bought this cosworth to go rallying in 11 years ago; he started to convert it to compete, therefore the interior was stripped and inside was painted white (a requirement for rallying apparently) and he welded in floor plates to accomdate the roll cage. He stripped the head off the car to put in a grp A headgasket...that's as far as he got, he's now sold the car to me with all the spares. The shell is solid and has no rust apart from on the bonnet. The car paintwork could do with tidying up in all honesty
i'm going to go about putting the head back on with help of another mechanic mate.
i need some bits for the engine, and as you people are well experienced with cosworths maybe you can help me
what the best places to get the following with regards to cost and quality
a) Grp A head gaket and gasket seal set (rocker, exhaust, inlet etc)
b) ARP head bolt set
c) timing belt & tensioner
d) water pump
e) engine oil (brand and grade)
f) gear box oil (brand and grade)
g) fuel pressure valve (the thing that site and the end of the fuel line)
h) all filters, oil, fuel & air
i'm sure there are some other bits too
PS. i'm based in Swindon, Wilts
The spares i got with the car is as follows: 205 block and sump complete with pistons, 2xcomplete heads, 2 rocker covers, spare rear bumper, spare steering wheel, 2 x LSD grpA diffs, spare gearbox minus the bell housing.
once i have the bits and start to build it, i'll post some more pics so you can see the progress
I've recenty bought a G plate 2wd Cosworth that's been stood for 11 years with 54k on the clock. the story goes as follows......
i bought it from a mechanic friend who has millions of cars (1 in fact is a RS500 which has been in storage since 1990) - he bought this cosworth to go rallying in 11 years ago; he started to convert it to compete, therefore the interior was stripped and inside was painted white (a requirement for rallying apparently) and he welded in floor plates to accomdate the roll cage. He stripped the head off the car to put in a grp A headgasket...that's as far as he got, he's now sold the car to me with all the spares. The shell is solid and has no rust apart from on the bonnet. The car paintwork could do with tidying up in all honesty
i'm going to go about putting the head back on with help of another mechanic mate.
i need some bits for the engine, and as you people are well experienced with cosworths maybe you can help me
what the best places to get the following with regards to cost and quality
a) Grp A head gaket and gasket seal set (rocker, exhaust, inlet etc)
b) ARP head bolt set
c) timing belt & tensioner
d) water pump
e) engine oil (brand and grade)
f) gear box oil (brand and grade)
g) fuel pressure valve (the thing that site and the end of the fuel line)
h) all filters, oil, fuel & air
i'm sure there are some other bits too
PS. i'm based in Swindon, Wilts
The spares i got with the car is as follows: 205 block and sump complete with pistons, 2xcomplete heads, 2 rocker covers, spare rear bumper, spare steering wheel, 2 x LSD grpA diffs, spare gearbox minus the bell housing.
once i have the bits and start to build it, i'll post some more pics so you can see the progress
12-11-2007, 11:53 AM
#2
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Good luck mate. Will be keepin an eye on this one. R u going to strip the inside of the car out and put it all back in so u know everythings ok, or is it all fine in there? just 11 years is a long time to be standing and u dont know if mice could of maybe got in behind the dashboard
14-11-2007, 04:17 PM
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Hello matey glad to see your putting it on the road, ( kind of 
)
As for the parts you need
a) Grp A head gaket and gasket seal set (rocker, exhaust, inlet etc)
b) ARP head bolt set
c) timing belt & tensioner
d) water pump
e) engine oil (brand and grade)
f) gear box oil (brand and grade)
g) fuel pressure valve (the thing that site and the end of the fuel line)
h) all filters, oil, fuel & air
These can be soursed very easy from the likes of, amber performance, p.j motorsport, woodford garage, graham goode racing, burton power ect all of these people supply the stuff so the choice is yours, i my self got a great deal from Jay at p.j motorsport and simon at woodford garage, there willing to come and go on some things like delivery and that too
As for the fuel pressure regulator i`d ask paul at north yorks, he`s a great guy to deal with and i`ve always had my parts as described and on time, he will also be able to get some parts that may be missing from the car that you dont no yet
Best of luck
)As for the parts you need
a) Grp A head gaket and gasket seal set (rocker, exhaust, inlet etc)
b) ARP head bolt set
c) timing belt & tensioner
d) water pump
e) engine oil (brand and grade)
f) gear box oil (brand and grade)
g) fuel pressure valve (the thing that site and the end of the fuel line)
h) all filters, oil, fuel & air
These can be soursed very easy from the likes of, amber performance, p.j motorsport, woodford garage, graham goode racing, burton power ect all of these people supply the stuff so the choice is yours, i my self got a great deal from Jay at p.j motorsport and simon at woodford garage, there willing to come and go on some things like delivery and that too
As for the fuel pressure regulator i`d ask paul at north yorks, he`s a great guy to deal with and i`ve always had my parts as described and on time, he will also be able to get some parts that may be missing from the car that you dont no yet
Best of luck
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15-11-2007, 07:29 PM
#12
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Originally Posted by NUTTIN RILLA
Get in the Q rat bags i`ve had first dibs on it 
Not after it myself,cloth is much more grippy and comfortable
Originally Posted by LHD220Turbo
needless to say i'll be bugging some people for some info/ help!
Matt
Matt
15-11-2007, 07:40 PM
#13
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Originally Posted by CosKev3
Originally Posted by NUTTIN RILLA
Get in the Q rat bags i`ve had first dibs on it
Not after it myself,cloth is much more grippy and comfortable
Originally Posted by LHD220Turbo
needless to say i'll be bugging some people for some info/ help!
Matt
Matt
You need to be quick around here
28-11-2007, 09:01 AM
#14
Quick update!
i got most of the parts i required now but progress has been a bit slow to be honest.
I've painted the block in silver and generally done some cleaning, i've mounted the ARP head bolts now and i've put the head back together including the exhaust, turbo and inlet.
i'm hoping to put the head back on by the weekend. its starting to take shape now. i'll take some pics and post them on the weekend
can someone help me wax oiling the underside of the car, anybody done this recently?
my question is:
what's the best product to use?
how much will i need?
Approx price?
and do i need to do any prep work beforehand or can i just spray/paint it on?
Any help greatfully received
i got most of the parts i required now but progress has been a bit slow to be honest.
I've painted the block in silver and generally done some cleaning, i've mounted the ARP head bolts now and i've put the head back together including the exhaust, turbo and inlet.
i'm hoping to put the head back on by the weekend. its starting to take shape now. i'll take some pics and post them on the weekend
can someone help me wax oiling the underside of the car, anybody done this recently?
my question is:
what's the best product to use?
how much will i need?
Approx price?
and do i need to do any prep work beforehand or can i just spray/paint it on?
Any help greatfully received
28-11-2007, 12:10 PM
#15
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What condition is the underside in m8?????
Any surface rust will need rubbing right down and treating with some rust killer,then a coat of primer before you put your wax oil top coat on
Don't be surprised to find some areas that need welding under there though
Check around where the rear springs sit on the chassis and where the beam bolts up
If you want to do the job properly though you need to drop all the rear suspension off,strip all the old underseal off,prime it all,stone chip it,then paint it body colour
Any surface rust will need rubbing right down and treating with some rust killer,then a coat of primer before you put your wax oil top coat on
Don't be surprised to find some areas that need welding under there though
Check around where the rear springs sit on the chassis and where the beam bolts up
If you want to do the job properly though you need to drop all the rear suspension off,strip all the old underseal off,prime it all,stone chip it,then paint it body colour
28-11-2007, 03:37 PM
#17
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I would only prime the areas of rust you have treated,or any areas of bare metal
I would use under body protector rather than wax oil if you want it black.
Use wax oil in all the chassis rails etc on the inside,will need a probe/pipe to spray it into all the openings
Not sure on quantity m8
I would use under body protector rather than wax oil if you want it black.
Use wax oil in all the chassis rails etc on the inside,will need a probe/pipe to spray it into all the openings
Not sure on quantity m8
17-12-2007, 08:07 PM
#20
Quick update - 17-12-2007
Quick update.
right'o - small update, the day started off so well.............
started to build the engine up today at the mechanics place. I had already painted the block and mounted the ARP head bolts so the morning was spent putting the head back together (cams, turbo, inlet & exhaust) mounted the head with the new Grp A head gasket and put the new cam belt on with tensioner....all was going well until i came to take the old spark plugs out...............so dumb twat must have done them up with a torque wrench!, 3 plugs have snapped off and are no stuck in th head!
i tell ya! - some spanner were thrown today
rest of the afternoon was spent removing the head, removing the cams, turbo etc and inlet - the head is HOPEFULLY going for machining tomorrow
does bad luck only ever happen to me?
on the brightside, i've put the prop in, and exhaust is now in place, also removed the old discs and clean up the calipers
tomorrow should prove interesting
i'll get some pics updated soon
right'o - small update, the day started off so well.............
started to build the engine up today at the mechanics place. I had already painted the block and mounted the ARP head bolts so the morning was spent putting the head back together (cams, turbo, inlet & exhaust) mounted the head with the new Grp A head gasket and put the new cam belt on with tensioner....all was going well until i came to take the old spark plugs out...............so dumb twat must have done them up with a torque wrench!, 3 plugs have snapped off and are no stuck in th head!
i tell ya! - some spanner were thrown today
rest of the afternoon was spent removing the head, removing the cams, turbo etc and inlet - the head is HOPEFULLY going for machining tomorrow
does bad luck only ever happen to me?
on the brightside, i've put the prop in, and exhaust is now in place, also removed the old discs and clean up the calipers
tomorrow should prove interesting
i'll get some pics updated soon
17-12-2007, 08:28 PM
#22
i would be to mate there is some muppets about done any more on the waxoil i have got a tub ready to the under neath of mine last time i looked under there it looked very good and just needed another coat
im not one for having a bufty underneath just want it to last
im not one for having a bufty underneath just want it to last
19-12-2007, 11:32 AM
#28
NeedForSpeed - hopefully planning for stage 3 eventually - just want ot get the thing running first and MOT'd - then next year i'll go for a set of dark greens, chip, 3 map bar sensor, decent clutch, exhaust and intake filter then take it too MA Developments hopefully for a set up
Last edited by LHD220Turbo; 14-06-2008 at 08:43 PM.
21-12-2007, 05:07 PM
#31
afternoon all;
right decieded not to get the head machined to have the spark plugs removed after all as it would have cost over Ł150
i've used a spare head i had which had a better deck height; stripped the head yesterday and took it to a tool maker who skimmed the head and removed 2 snapped studs, he's done a cracking job and only charged me Ł40
The bad thing is one of the chambers was covered shite so i'm going to replace all the value stem seals. Hopefully i'll get the head finished tomorrow and then i'm ready to finish the engine and fire her up for the first time in 11 years............to be honest i'm bricking it slighty in case something goes wrong and i end up having to strip the engine again!
i'll post some pics up of the head if i remeber to take the camera down the workshop
any tips from anyone on running the engine up for the first time?
i've bought 2 oil filters and was planning to run it up on cheaper oil first then stick some silkolene in it
right decieded not to get the head machined to have the spark plugs removed after all as it would have cost over Ł150
i've used a spare head i had which had a better deck height; stripped the head yesterday and took it to a tool maker who skimmed the head and removed 2 snapped studs, he's done a cracking job and only charged me Ł40
The bad thing is one of the chambers was covered shite so i'm going to replace all the value stem seals. Hopefully i'll get the head finished tomorrow and then i'm ready to finish the engine and fire her up for the first time in 11 years............to be honest i'm bricking it slighty in case something goes wrong and i end up having to strip the engine again!
i'll post some pics up of the head if i remeber to take the camera down the workshop
any tips from anyone on running the engine up for the first time?
i've bought 2 oil filters and was planning to run it up on cheaper oil first then stick some silkolene in it
23-12-2007, 06:40 PM
#32
here's some pics
the head is finished now, its been a right pain in the arse, all the valve stem seals have been changed and the valves have been lapped in.
i've got a complete cometic gasket set which includes the head gasket, you can see the new exhaust gaskets in the pics
tomorrow (after work) providing i can get a fuel filter i might try and fire her up providing i can get the head put on OK.
the head is finished now, its been a right pain in the arse, all the valve stem seals have been changed and the valves have been lapped in.
i've got a complete cometic gasket set which includes the head gasket, you can see the new exhaust gaskets in the pics
tomorrow (after work) providing i can get a fuel filter i might try and fire her up providing i can get the head put on OK.
04-02-2008, 05:17 PM
#36
AJC
not yet!! - as i've built her up i've realised i've had a few more bits missing, so i've today ordered some more bits from Paul at North Yorks (top man as well) so....providing i can use my mechanics workshop this weekend i'm hoping to fire her up.
i'll record a video of the event and post it here, fingers crossed!
not yet!! - as i've built her up i've realised i've had a few more bits missing, so i've today ordered some more bits from Paul at North Yorks (top man as well) so....providing i can use my mechanics workshop this weekend i'm hoping to fire her up.
i'll record a video of the event and post it here, fingers crossed!
