saff re, re-build.. smooth bay. RS500 style bumper bought another saff update 17/3/11

[jaimesdna]

thought i'd finally start a resto thread. re built the car about 4 years ago from a bare shell. unfortunatlly after 6000 miles one of the long studs broke, meaning the engine had to come apart again. here are a few pics from the original build to give an idear what the car was like before it came apart again then the wheels painted white the cossy was used on my wedding day to take the wife to church and now on to the current re-build the offending stud 3 gueses where the rest of the stud was. luckly a mate of mine is a prescition engeneer & was able to remove the broken part pretty easly after the engine was stripped whilst the engine is out i've decided to smooth the engine bay & slam panel

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[Brian]

Brian

[LHD220Turbo]

how clean is that; love it on the white rims

awesome bud, credit to you!

[jaimesdna]

a light skim of filler to see how thing are going



the curve of this side of the slam panel is different to the passanger side so i made a template of the curve. cut slits into a piece of angle to bend it to the correct curve then welded it into shape

taked into place

welded in & ground down


another skim of filler

shoud hopefully be able to rub down the filler tomorrow to see how much more work needs doing

[KSA-Cossie]

Bufty Very nice indeed though m8.

[moonstone_cossie]

wow looks good cant wait to see it all painted!

keep up the good work!!

[jaimesdna]

you'll have a long time to wait to see it painted due to my lazyness lol

[jaimesdna]

i'm thinking about painting the whole car in base white. should dazzle a few people

[hai07222]

Looks really nice. good work

[clarke5700]

dat looks rude mate very nice

[jaimesdna]

done sone more work this morning on the slam panel. just smoothing filler. there really is a nack to filler & i've just not got it lol

[Moonstone Mart]

looks great james.

where did you get the RL7's from? They 18's?


Mart.

[fezzajsy]

looks wicked...

[Twins]

Looks great ,you cant beat a nice smooth engine bay

[cossie690]

look's fookin lovely..

nice work keep the pic's comin..

imo you should colour code the alloy's tho..

[jaimesdna]

Originally Posted by Moonstone Mart

looks great james.

where did you get the RL7's from? They 18's?


Mart.

they were advertised in the back of fast ford about 5 years ago. cost Ł200 but there was a 500mile round trip to go & get them. yes they are 18's

[jaimesdna]

Originally Posted by cossie690

look's fookin lovely..

nice work keep the pic's comin..

imo you should colour code the alloy's tho..

the whole car is gonna be painted base white (the whitest white), if the wheels stay white i'll re paint them the same white

[C8SEE]

I really like that!! Very very very nice!!

[cossie690]

Originally Posted by jaimesdna

the whole car is gonna be painted base white (the whitest white), if the wheels stay white i'll re paint them the same white

that's kinda what i'm doin with mineat the mo.. it aintgetting resprayed diamond white.

it's a lot whiter than the creamy diamond white..

[sortedsaff]

very very nice . some top work there

[jaimesdna]

cossie690 there are a few posts on here somewhere about alternative whites. moste people said the whiteset white was the base white used to mix all other whites.

[cossie690]

Originally Posted by jaimesdna

cossie690 there are a few posts on here somewhere about alternative whites. moste people said the whiteset white was the base white used to mix all other whites.

yup. it is. i paint for a living. the base white we used was well er.. really white. i'm doin mine a kinda blueish white tho.


can't wait till it's finished!!

[SOO]

thats coming along nicely.

[cossiegreg1]

that looks real nice i like it.
what springs do you have on the back? what does it drive llike bein that low? have you got shims on the back? and one more question lol, where did you get the fuel pump cradle? cheers mate. good luck with the rebuild

[jaimesdna]

they are castle performance springs. handling is ok, im sure it would be much better if it sat a bit higher so that is a bit of a compremise i guess. yes it has got some shims on the rear courtesy of mike r. the fuel pump cradle is just the standard one been powder coated silver

[marky_g]

cool never seen a saff done like that

[jaimesdna]

never really liked the tow eye, so off that came. there was also a repair needed to the cross member wher the meta is double skinned & water had got in. all the rot was cut out & replaced with 2mm steel





this leaves the problem of no tow eye. so thanks to my mate tony a new one was made. the actual tow eye was from his old fiat bravo. he then drilled & tapped a piece of round bar to screw it into & cut some strenghting plated to weld round it. then weld them to the cross member. i was gonna fit this to the middle of the crossmember but i'm now thing it will probably just cause it to bend, it will probably be welded to one side


the bottom end is now back together with the help from tony
all the old parts were checked & re used as they had only done 6000 miles. the compression was lowered & valve cut outs were done by harvey gibbs courtesy of mike r

also new high quality long studs were purchased from mike r, so hopefully wont be having any problems with these

after a long time searching for a good head with lots of life left in it i finally founf this on ebay for Ł650. its fully ported & has double valve springs. it was check by harvey through mike r & found to be a good head.




as the engine is long studded it causes problems doing up the nuts as you cant get a 18mm socket in the holes. so there are two choices, machine down a socket or machine the holes bigger. as i thought id probably just end up loosing the socket i guesse it'd be a better option to machine the head. this was done by another mate of mine who is a precition engeneer. he is the same person that machined the broken studs out of the block.


these are some of the other parts i have brought
alloy air box lid to fit a t4 inlet pipe. Ł70 off ebay. i'm really happy with it. the quality is excelent



verniers from jasesapphy
.

i also got some brembo 8 pot calipers from an amg merc. these really are huge


i will get some audi rs4 356mm disks to go with these when i have spare cash
i mocked up some disks just to make sure they fit behing the wheels

[jaimesdna]

after a long time searching i finally found a small turbo plenum chamber. these thing are like rocking horse shit to find & normally cost a fortune. i got this from a passion ford member (cant remember who) for Ł150 delivered. i'll probably get the hole for the air charges sensor welded up & moved to the middle. then get it powder coated the same as the old one

[sortedsaff]

great work loving the amg calipers

ill keep my eye on this

[jaimesdna]

here's a small up date. finally started the passanger side inner wing


not too sure what this hole is for, so out it came










thats about it, will update again soon

[Kverna]

Fav project of the month! Keep up the good work

[fezzajsy]

looks awesome

[sortedsaff]

looking sweet as always bud keep it up

[Simmo]

Only just spotted this... top work!!!

I'll be keeping an eye on this...

[col cos1]

great work there mate,they calipers look peak

[fiesta_xr2i]

like the under bonnet job alot

MORE PICS

[jaimesdna]

update time. its been cold so i've been avoiding going out int the garage unitill i got a heater. after looking i found this on ebay

so im now running out of excuces to not not go out there

i sold the amg calipers as it was gonna cost a fortune to get disks bell etc.
so with a big thanx to NUTS RuS i got these. 350mm disks & brembo 4 pot calipers. the calipers will be painted white to match the car



the tow eye is now welded in with strengthining plates




oil cooler brackets are welded in althout im not gonna be running the oil cooler at the moment


ive brought some aero catches to hold the front bumper on




i had to make some drop brackets to mount them but i'll add some pics of them later

finally today i got the bay in primer, dusted with black & ready to rub down

[fezzajsy]

looking good..brakes look awesome.how much were they? pm me if you prefer

[saph cos rob]

looks spot on mate! think i might copy your idea of the heater! then i havent got a excuse not to get some more done on mine!!!

[hitchwest]

lookin good mate i think the RL7s look awesome in white mate