olek

hi, thought i would put up a project-thread on my 2wd sapphire, to get feedbacks, comments and maybe an advise or two.

i'm gonna try to take i all from the beginning when i bought the car 2 years ago, i got it cheap, mainly because a bad engine and some rust. on the good side the car was fitted with a lot of good parts, and i got a spare 200-engine.

this is how the car looked like when i got it:

at the time running greys, mountune chip, turbonetics e-50 and all the usuall stuff.

the engine had a low oil pressure, was ratteling badly and generally misbehaving. i could drive it with 0.7 bar boost, but as soon as i set the boost to 1 bar or more, the car would suddently start to fire only on 3 cylinders. the electrode of the spark plug was jammed in each time the problem occured. also, remember, the engine had som really bad rattles, this was the reason:



the problem was mainly on cyl 4 but there was marks on all other cylinders, i have NO IDEA what the previous owner has been up to.

well, the engine was stripped, all use-able parts was put to side and the rest was scrapped. i rebuild the engine with the rebored 200-block, mahle pistons, balanced bottom end ++. the turbo was also scrapped since all the blades on the exhaust-wheel was damaged. bought a new Presicion SC44 turbo and bolted the engine back together.

all this was during the fall/winter 2005/2006 and in the easter 2006 we started to rust-weld all the rust that was on the car. me and a mate worked about 12-16 hours a day in 10 days to get it all finished

this is just some of the rust!

wasn't finished putting the car back together before late august 2006, just drove it some months, took it to one trackday (no picture, sorry)

i drove the car just ONE day to much....took the car to work a cold morning, had the original wheels with studded nokian hakkapelitta tyres on (well, the studs had been torn out, the tyres were ment to be used on a trackday) came all the way to work and on the parking lot the ground was frozen. to much speed + ice + crappy tyres =


came sideways over the parking lot and straight into a solid building (the irony was that the building was owned by a tyre-company... )

the "only" damage was to the wings, rear bumber and a broken mirror. nothing on the doors...

well, a good reason to respray the car!
fall/winter 06/07 some work was needed on the car


the car when to the bodyshop and came back all white, will come back to this one, once i found the pictures...

the colour is just plain base white, no diamond white here as i think it may look a little bit yellow og grey sometimes. base white is soo much purer and cleaner!

also, wanted a little more power now, so bd16+ cams and pectel t2. the cams required the pistons to be pocketed and the head to be machined to accept double valve spring. this ment that the engine had to be stripped again, i also got jenspeed to machine the block for 4 long-studs. jens
also machined the pistons and the head. since the head was already ported this wasn't needed now.

put the engine back together and timed up the cams


didn't have time/money to mount and map the pectel now so the engine was still run on the mountune chip and grey injectors

drove at about 6-7 trackdays during the summer, with the diff collapsing at the second trackday.
borrowed a spare 7" diff and axels from a mate, welded it properly

some trackday-pics




but the co-driver/mechanic didn't seem to matter


i think this one looks cool, didn't have the sideskirts mounted, one of the first trackdays


the white paint is falling off!!


at the last trackday, wich was a small almost private one, the 6-pad clutch went and stucked itself to the flywheel, it was almost welded stuck! got hold of a new 6-pad, got the flywheel skimmed and put it together only to find out that the syncro-ring on third gear had gone. got sick of the car and didn't see it for a month or so.

finally got some motivasion (?) back and decided that the car was goiing to be a proper trackday-toy.

so out with all the interior, bar the upper part of the dash. also remowed all sound-shit and cleaned it


next step was to weld in a proper rollcage, first we stripped the car and took of the doors for easy access


then the welding started


the cage is build after the regulations that are needed to get a licence. since the car is still goiing to be "road-legal" and have plates, i need this licence.

the cage was also welded to the a-pillar and b-pillar for extra security and stiffness.

a-pillar shown here

the cage was also linked to the front turrets


the car is just gonna have the cage, 2 bucket-seats with 4-point harness, upper part of dash, the needed gauges and aluminium or carbon plates on doors etc. all you need to have fun!

i'm also goiing to wire up a completly new wire-harness, with just what i need and nothing more.

so, what main things to be done this winter:
get the inside painted white
mount everything inside
new gaz golds
wire up a new harness
change syncro-rings on the t5
mount and map the pectel
new 750cc injectors
maybe a big-brake thing up front
maybe strip the underside and paint it

so, there you have it, i will try to update as soon as anything gets done on the car.

will come back to you guys with the full spec of the car if anyone wants to know.

please comment, ask or just have a look

Lee1

Good to see it getting used how it should be

Mr.T

nice project you have there. Well and the ice??..... i had the same in norway 2 years ago

fezzajsy

iTrader: (9)

olek

thanks for the comments

also, forgot to mention that i've bought a hydraulic handbrake



i'm also goiing to modify my steering rack even more, so that the powerslide-angle will be bigger

cheers!

NEEDFORSPEED

spot on!

JHS

iTrader: (1)

Well done, looking good...

Har du ordnet med godkjenning av buret?

JHS

iTrader: (1)

On a nice straight road...

Si B

iTrader: (59)

Great pics and cool project - keep us updated

CosKev3

Good thread

Mines base white

As you say makes Diamond white look like cream colour

olek

yeah, i was never in doubt about the color. also, white just screams motorsport!

JHS: det er jo nye regler ang bur i gatebiler nĺ, har ogsĺ diskutert dette med mitt lokale biltilsyn, og sĺ lenge bilen er lisensiert i en motorsportsgren og at buret ikke stenger noen nřdutganger, dvs ikke kryss i taket ved takluke og avskrudde dřrstevere pĺ vanlig vei

kommer til ĺ lisensiere den i drifting, der er jo nesten alt fritt, hehe

eneste jeg er "bekymret" over er břttestoler og 4-punkts belter, selv om det er FIA-godkjent...

Twins

iTrader: (18)

Awesome project

Simmo

iTrader: (20)

I like very much!!!

Mr.T

Yes with a cm of ice. Even the recovery truck had troubles But no prob. The car didnt had a scratch only problem was that 1 day later the head cracked Had to leave him there.

Ruudsengen

Nice project. Keep posting pics.

Adressa di du har bilde av der eller?

olek

thanks for all the comments, guys!

ruudsengen: hehe, alldeles ikke, uber-gammel adresse til samboer. bilen stĺr heller ikke pĺ noen adresser tilknyttet meg eller min familie sĺ it's safe!

CliffRS4

iTrader: (1)

Loving the work that's gone and going into this car

olek

thanks, cliff s1!

i'm hoping to pass 500 bhp with no serious problems, the car will be mapped on a dynapack, so when the dynapack says the engine got 500 bhp, it has!

there's soo many that hit 500 bhp in the dyno, and when you get the car on a rolling road later, with all the car'a ancilliaries such as exhaust, intercooler, pipes and so on, the engine drops to around 400-450 bhp.
it also shows up at drag-strips. several "500bhpextremecossies" gets their asses kicked by a good stage3 cossie....

i want a REAL 500 bhp car.

also, there's so much things i want for mye engine this year such as a new intake manifold and a new exhaust manifold. 500 should not be problem with these items to, but they cost soo much!

but hey, money is made to be used, aren't it??

Ruudsengen

fiesta_xr2i

dette blir bra

tipper britene IKKE liker norsk

t3 dan

iTrader: (2)

olek

found some pictures of it when it was painted.

first i rewelded the front bumber fasteners to get the front bumber totally alligned




off to the bodyshop then



and back from the bodyshop in clear white!





gonna start to sand down the floor and get it prepped for paint this week. was hoping to be totally finished with the "interior" on this side of new-year but....time will show

kitchy

just read the whole thing love it mate

your right about money being there to spend, you cant take it with you as my dad always says

carlo

iTrader: (4)

Top work there fella

Alan s1

Looking good m8 i have also stipped my 2wd cossie out and putting a bolt in 6 point cage in it

olek

been in the workshop today, most on the floor has now been filled and sanded down, ready for paint. just need some welding done to the bulkhead and on the floor where the original plastic-covers was.

took a few pictures of the cage as well, enjoy







rearview!


also fitted the outer part of the battery master switch


this cosworth belongs to a friend of mine and is in for a full body-overhaul


another friends 944turbo is getting the engine rebuild't

olek

also, it's now getting ready for mr license-guy to come and have a look, fingers crossed!

Billy_RS

iTrader: (5)

I have a feeling this is going to be mental


Keep up the good work

Samatron

JeroentjeJeroentjeRS
RS

hello i saw this picture: http://img.photobucket.com/albums/v2...n/PICT1568.jpg

this was on the Dovrefjell? and you had to leave the car on Dombĺs Bil rigth?? i live in dombĺs and remember you sierra!

cheers!

Alan s1

Did the same to mine




Keep the good work up mines take me 2yrs +++ now and still in the garage in bits

olek

thanks billy_RST, don't know if it's gonna be mental but...

thanks alan_s1, not going to do it the way you did on the decompression-sones, the plates i'm putting there is going to be sikaflexed and fastened with pop-rivets. the round plastic-thingys is going to be welded like yours.
as we all know the ford's have a bad habbit of start rusting where the plates meet and is welded on the car, was hoping to prevent this as to not weld the plates.

still can't decide if i should bin the central-locking or not, would be much easier with the cable-streching and all, but it's also very convinient(?) to have. any inputs on this guys?

all the wiring, fuel hoses and brake lines is going to the middle of the car, gonna try to gather it and hide it as much as possible...

Alan s1

olek I have taken all my Central locking out The rear doors wont be in use as the cage will be in the way and im guessing your having no back seats in there so they can stay locked

But i am keeping the Electric window

olek

the electric windows on my front doors is staying in mine as well. the rears doesn't have it.

gonna have an extra look and think how the wiring is gonna be, but as things look know, the central locking has to go... all i need then is the switches in the doors for the orginal roof-light, so that my alarm would still work.

is yours going to be a trackday-car as well? any project-thread here?

Alan s1

Well that was the Aim but i think it will fauil nosie testing as it has a Side Exit exhaust and is 4inch from the turbo

Yes there is a thead on here some where i have to keep stopping it due to money ect but atm im waiting on my m8 to paint the inside so that the cage can go in and i can then move on with the wiring ect (not looking falward to that

Alan s1

olek Here you go mine so far
https://passionford.com/forum/viewto...=asc&start=494

olek

finaly got my new injectors today, siemens deks genesis 750cc

bought from usrallyteam.com , nice guys, fast shipping and great prices! recommended!

i'm hoping to get a trigger-ring for the crank-sensor in a week. can't wait to get it started up with the pectel

cheers guys!

Alan s1

Whots a "Tiger-ring"
Also good move getting the Siemens injectors go got aset in mine only the 55lbp tho

olek

alan, haha, trigger-ring is the 36-1 ring on the crank pulley, that sends the signal about the engine speed. REALLY bad explanation, haha!

gonna order up some an-couplings now

Alan s1

Ok

rand

Looking very

I'm considering stripping and caging my saff,
think this thread may of put me in the right frame of mind to go for it!!

Good luck for the rest of the build mate