Ebonycossie4x4

iTrader: (4)

Found an Extremely clean J reg ebony black 4x4 about 3 weeks ago now. had all the right bits, coilovers... big brakes up front alloy rad, cooler, wrc breather, swirl pot. 85000 miles from new every mot and nearly full service history, underneath is mint etc etc 15000 reciepts
Anyway Car was smoking very heavily so bought it cheap and set about stripping down the engine. Found that as usual with cossies someones been there before but engine was completely standard. slight lip on top of bores, cracked ring and destroyed shell due to major overtightening on end cap.

Anyway ive put the engine in to a tuning company near me more renound for jap cars but im certainly paying for it lol.

This is the spec, let me know what you think.

Long studded 200 block
Overbored for exact match
Wossner pistons with teflon skirts
Valve cut outs as required
Low compression
Shot peened rods
Full arp bolt and nut kit throughout
ACL RACE Bearings
Good as new unground CRANKSHAFT all uprated bearings
High pressure oil pump Fully balanced bottom end
2 x BD14 cams With verniers
Bronze valve guides and valves reseated
Double Valve Springs
4 layer Wrc Headgasket
GT35 Turbo
Tial external wastegate
Massive headwork for a 25 % increase in flow.
Swedish plenum.
6 paddle alcon.
Weight Matched Bottom End.
All being powder coated and dressed up.

(costing best part of 12 grand.)

Does that sound expensive.

Once ive restored some funds back to my wallet we are going for autronic management with 1000cc siemens injectors, low boost anti lag and launch control.

Going for 550bhp+ so i can beat my dads m5 lol.

Sorry about the long post any feedback would be great....

Oh and im still with the standard gearbox for the mo.

zetecapri

Lot of money but will definiteley be worth it in the end Get some pictures up, a mate of mine has a black one too.

Ebonycossie4x4

iTrader: (4)

ill take some pics at the weekend mate... been polishing it for hours while the engines out. Its really clean now just cant wait for engine to be finished. Any advice while car is in build stage would be great.

rapidcossie

sounds about right...

who is doing the work?

Ebonycossie4x4

iTrader: (4)

Torque developments down here in essex. they seem expensive compared to some but are doing a great job. As you have a seriously fast cossie already do you have any advice? Is 500 bhp achievable in real figures and not pub talk with my setup?

cameron2

Get pics up mate

fezzajsy

iTrader: (9)

sound a good project..pics pliizz

Ebonycossie4x4

iTrader: (4)

cars in my mums garage at the moment while the engines outas im using my bros hoist. ill get some ics up asap. Probably saturday though as when i get in from work its dark. It has ozsuper ts on it but i would say the rear ones are too far into the arch. if i extend the wheel studs and use spacers is that a safe way to do it as the car is going to be 500 bhp???

Thankyou

DENNIS

nice project

"been polishing it for hours while the engines out" a true bufty... just like me

PM sent...

Ebonycossie4x4

iTrader: (4)

Here are some pics of what it was like before the engine came out
IMG]http://i258.photobucket.com/albums/hh246/rapluvalways/9a40_4.jpg[/IMG]

Ebonycossie4x4

iTrader: (4)

i hate the way the wheel is into the arch on the back...

Any advice on this would be great, i have considered longer studs and wheel spacers as i love super ts and dont wanna give them up unless i get compomotive mos in anthracite but its another 1000 i really dont wanna be spending with the cost of the engine build

Any advice would be great.... Cheers

Ebonycossie4x4

iTrader: (4)

Alcon 6 paddle has arrived with collins anodised blue engine mounts. Ordered pro alloy twin high performance fan setup at Ł170 Inc vat. Expensive but looks great and should really help cooling.
Pistons have arrived for the engine and block is at machine shop for long studding and everything else that needs doing.
Still waiting on a price for a gt30 turbo or gt35 with external wastegate. With the spec of the engine and the fact that im gonna run autronics what would people recommend. I looked at a t38 but its old technology now and really want to build to a high spec

Any advice is always appreciated.

Any costings of turbos from other people would also be great

Thanks.

-beefy-

iTrader: (6)

surely your going to need head work for 500 bhp fella ?

or aleast hold the build up till you can afford it , seems a waste not to have it done in one hit bud ?

Ebonycossie4x4

iTrader: (4)

I know mate was in the engine builders on saturday and they

(talked me into)

Doing it in one hit.

Massive head work being done. Same as dennis's Escort Cosworth Ill try and get a pic. Thanks for reminding me i forgot to update that.

Dont think there was any way i would of realistically got the power i want from not doing the headwork so its got to be done.

Ebonycossie4x4

iTrader: (4)

Hope dennis does not mind about me borrowing his pics lol.




This is the spec ive requested. I believe he is doing exactly the same due to the massive improvement he saw on the flow bench....

Hopefully he will correct me if im wrong

CosKev3

Looks a nice one

Going to be a flier with that spec too

Standard gearbox though think you need to budget a few grand for uprated box and diffs if you want to use the power you will have

Ebonycossie4x4

iTrader: (4)

are these boxes really as weak as people say. My last cossie was 380bhp and i never had a gearbox problem (until it come away from the engine while doing some serious speed round a bend0

Causing me to have a very painfull accident but thats a very different story.

The only thing i ever noticed is a noise as slamming it into 3rd when racing through the gears. How long do people predict before the standard gearbox blows on this spec?

is a gearbox that wont break about Ł3000

Suppose i better get saving.

CosKev3

Once you have done the box the diffs will shit there selves!!!!!!!

All depends on how you drive the car,drive like your mum and they will last forever
Give it a few hard launches from a standing start and the box will break

Big jump from 380bhp to 500 bhp on the stress to drive train

Ebonycossie4x4

iTrader: (4)

yes i suppose it is quite a big jump really i do like a hard launch (showing off)

But if its going to cost me 3 grand or 150 putting another second hand one in everytime i do it i think ill launch it a lot less.
I plan on getting a apexi boost controller and run 350bhp most of the time and 500+ when i need to Anihalate someone

Thanks for the replys diffs are 1000 each arnt they?

Dan

Looks a lovely clean car mate!

fezzajsy

iTrader: (9)

looks very good

DENNIS

I don't mind you using the pics mate..

you will be surprised how much these boxes will actually take ( not saying i have not broken any )

i give my one loads of stick , mainly launches...

blown a viscus coupling and broken a 3rd gear..

but most of all done a fair few clutch`s


i would advise a front diff strengthening plate though.. as its keeping my ones alive

just saving up for the proper box i want..

Ebonycossie4x4

iTrader: (4)

what is this plate then Dennis and where do i get it. If its worth doing while the engines out then i could have a look

Thanks mate

DENNIS

it would go in between the front diff and diff lower pan..

i can get one if need be..

Ebonycossie4x4

iTrader: (4)

Car coming along a bit now Drilled out snapped intercooler bolt. cleaned it up and put cooler back in position with new bolts and rubber spacers. Also my fans and bracket arrived which i have put on to the now cleaned up radiator, and its back in the car for the time being so fans can be wired up with switch easier.
Things are coming on quite nicely at the moment.

My bad bit of news about the crank being scrap due to crack is now sorted.

Thanks to RapidFord the crank i purchased from them is excellent. After examination from machine shop, its not cracked never been ground and its perfectly strieght. Just needs lapping. The bloke there was genuinely impressed.

Ebonycossie4x4

iTrader: (4)

just a quick update (sorry about no pics) Will post them when i get a chance.

Ordered my gt35 turbo today with tial external wastegate from reyland. Got all the extras so that its ready to bolt in, Have also got the 4 inch blue pipe and larger airfilter for it.

My new wheelnuts, longer studs and spacers arrived today so over the weekend i will be fitting them to get my wheels to fit in the arch better.

In the morning im going to order my swedish plenum from Mike and possibly the 70mm Throttle body.....

Will i need this????

i think were gonna be more like high 500s with this spec now although i think 2x bd14 is bot the right way to go? Maybe a bd16 somewhere. im in the hands of the engine builder at the moment so i dont know.

Another point to make is that im buying all this stuff but the autronics is not going to go on for at least a month as i need to run it in and replenish some funds.

is it going to be run inble with all this extra stuff and only on greens and the same fueling as before. Im installing the engine back into the car so will prob have to go back to have the fuel adjusted

Any advice is always greatly appreciated as all this can get confusing

Thanks Guys

Lambchop

iTrader: (1)

nice project

ebony saffs are rather nice

good luck with your transmission tho

Ebonycossie4x4

iTrader: (4)

this is a pic of the car today, Its going quite well. Ive run thicker gauge cable strieght from the battery for uprated fuel pump. (when i get it) Ive also fitted the studs, spacers and nuts to the car and in my opinion it looks a million times better.

I only currently have the pic of before the studs so you will have to bear with me.

rapidcossie

coming together now

KSA-Cossie

iTrader: (4)

Looks much better now m8.

Ebonycossie4x4

iTrader: (4)

thanks Guys.

Ill be posting more pics as the new parts arrive. The GT35 is coming wednesday with external wastegate i hope, so i will take some pics as soon as all the bits start to arrive

DENNIS

Hi, the BD 14`s are best suited to your application as the power band on the BD16`s is 3500 - 8500 RPM and are not really suitable on a road car as you would have next to no idle, flat below 3500 rpm and would need to rev it to 9000 rpm + to make use of them, ( and a dry sump system !! ) which would need a very different engine build to work best...

the intake system is a very good idea, as recent flow tests showed up just how bad the standard item is..

as for the running in, you would not want to damage the new engine in anyway, and would need to be very careful on first start up, but best suggestion would be to have the fulling checked on start up as with the new set up i would expect it to run very lean...

GUZZLER

iTrader: (3)

looks a nice car, after seeing Dennis's engine i thought people would be using TDI
my car has run near 450bhp since last summer on a standard gearbox, i have a mullit box but havn't bothered fitting it yet......


cossie aside, is that an interceptor on the drive?

Martin-Hadland

iTrader: (2)

Is that a joke?? Please tell me you are not serious... The next to no idle comment is a blinder Sorry to have to say this but your advice is not good

Ebonycossie4x4

iTrader: (4)

Problem is dennis that obviosly im installing the engine myself once its built and dont have a fueling check system. Im obviosly going to bring it down to you at tdi to adjust the fueling (is this best on a trailer or is it ok to drive) I have been told im going to have to change oil every 50 miles for first 500... is that true?

i dont think the bd14s are too much of a problem. Im not attempting to strain every last bhp out of the car but if it is a problem then 150 for a new cam is not going to kill me.

oh and yes it is an interceptor, its my stepfathers pride and joy that would usually be in the garage if it wernt for my younger brothers rs turbo taking up both sides of it.

Thanks for all the help guys

Martin-Hadland

iTrader: (2)

Here are most of your bits

Ebonycossie4x4

iTrader: (4)

Ok mate Cheers

Look forward to recieving it all.

NEIL A

iTrader: (6)

Agree with martin my car is running similar spec cams to BD16's and idles ok once its warm and thats without a iscv at the moment.

Stavros

Cool car

Im deffo agreeing with the thing about why would a BD16 give you bad idle and low down power? Its only a fairly mild 265 duration, almost identical to a BD10, just with loads more lift.

Not exactly some 320deg race cam is it!

DENNIS

my point was that these cams are not suitable on a road car with a power band out side the window of use, thus not suitable on this application.

as for the idle.. OK no idle was maybe a bit of an exaggeration, but from experience there not very smooth at all, OK on a race car where its on high revs all the time, but not on a road car ....