Here We Go Again.... Strip down Commences. Smokestone K Plate

[Ebonycossie4x4]

Right. ive quickly got fed up with the timewasters and messers bidding me down constantly on this car, so ive decided to keep it (for a while) and buy my escos when i have enough money from other means. In my opinion its the best colour and its a reasonably tidy shell (a good base to start from anyway) so im going to sort the problems. This is not going to be a big money project and although im mechanically competent i am no wizz when it comes to a set of spanners! I do however have a big double garage with adequate lighting and time on my hands. So lets get going. Right. The issues. BLUE SMOKE ON BOOST!!!! Annoying the hell out of me and extremely embaressing. I wont go into other niggly problems until this problem is atleast diagnosed. Tonight i started stripping down. heres the car. Heres The Bay All comments welcome. Whos betting im going to see a puddle of oil when i lift the head off....

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[Ebonycossie4x4]

heres whats happened tonight.



This is a gasket apparently...



heres the head so far.



And heres how we are left tonight





Ive hit a stumbling block as i cant get head off as its weird socket star key thing.

Anyone know what i need to buy asap so i can get head off tommorow.

[timster]

It is the correct gasket but when you refit put some sealer either side of the seals to hold them in place when re-fitting the rocker cover.I know they're torx on them can't remember the size though.Haven't done a cossie head gasket for over five years.Hopefully someone on here will help you out

[Ebonycossie4x4]

Cant be correct gasket as it really wasnt a gasket lol....

Just looked like orange mastic.

Thanks for the input, i thought it was gonna be normal bolts but torx bits instead.

maybe if i go to halfords and get a set.

Anyone with some help would be good.

Cheers

[cossie*mad!]

Blue smoke on boost - I take it youve inspected the turbo for seals gone / play in the shaft before trying to take the head off? It would smoke all the time if it was the rings gone surely...not just on boost (that was my symptoms anyway)

[timster]

Shit thats bad Just surfing the net to see if i can find any info on the torx size.The orange seals you can still get from fords or any of the traders on here

[Ebonycossie4x4]

there is tiny side to side shaft play in the turbo but nothing major.

im pretty sure that it can be piston rings and not smoke until on boost.

The main aim is to whip the head off and inspect as best as i can for valve guide issues. Or take to Joe and ask him (pay Him) to give me the low down.

Also once ive got head off have a look at pistons and bore etc etc. see if oil is in chamber above pistons.


Then rebuild bottom end lol....

Not going mega though.

This is budget build as money is saving for escos.

[C8SEE]

Did you try putting on a breather system?

[AJC]

good to see another getting some tlc

[Ebonycossie4x4]

spoke to lots of people that said breather system will make no difference as its only stag 3 running 20 psi.

When cold it fills the road behind with blue smoke, This is not just a little bit. I like the car its reasonably clean so i thought why not.

Saves another one from the breakers.

Have got 4 days off so i will be updating the thread a lot hopefully.

i dont know whether to hope for valve guides or rings....

Rings means ive gotta take the engine completely out and i cant say i fancy that lol...

[Brian]

Good luck with it mate


Brian

[Ebonycossie4x4]

Right quick update.

head is now off and waiting to go to GS Motorsport. To be honest i cant really see any problem other than it being a bit coked up on the bottoms of the valves.

Have some pics that i will share later.

[RST]

Good luck with it mate keep the pics coming.

[hai07222]

As said above, nice to see another one being kept alive. Good luck with it

[Robs Frst]

Nice to see 1 getting looked after, good luck

[TurboShed]

I'll give you Ł400 and my Corsa for it

Yes nice to see another getting looked after. I'm currently scrapping a rotten one, and reshelling into a lovely straight car, top banana, just wish it wasn't taking so long

[Ebonycossie4x4]

picking up my escos shell in the morning so looks like this shell is going to be redundant.

Will update with pics in the morning.

Engines out and head is with joe already. he will be receiving bottom end soon too.

Looks like its going to be a long one though lol.

Take my time and make it a real nice one.

hoping for maybe realistic 450hp in the long run...

[Ebonycossie4x4]

Right...

Escos deal didnt come off due to seller being just too unreasonable for me.

Anyway onwards and upwards...





Head is out the car and stripped. Found head to be in a good condition and far too cleaning leading us to beleive that someone had already been up that garden path. So i got back from joes and started stripping the bottom end out.



bottom end is out and sump is off...

I found a quarter of a rubber glove and loads of like masticy rubbish all stuck to the pick up pipe...

What is it with me and cossies. Gotta stop buying cheap ones.

I dont want to go spending thousands on it and joe being the kind of guy that he is has said that i can do as little or as much myself as i want.

im now just going to go for a nice usable stage 3 build so i dont think i will even be going low compression.


honestly cannot praise GS Motosport enough, So understanding and Joe is a top Bloke...

Will grab some more pics when i can. Car is currently looking very sorry for its self in my garage.

Anyone know where to get the bits of the front wings that the bupper attaches too as they are quite rusty and ive heard you can buy them rather than new wings.

Cheers

Rob

[RONNIE AMIS]

good luck with it mate, joe is very good aint he, he doesnt get as much praise as he deserves i think

could go the breakers and cut some bumper mounts off couldnt u?

[Ebonycossie4x4]

Thanks Ron...

No he does not get the praise he deserves. I wish i could get the engine built by him but just cant warrent going the whole hog on it until i get something nicer.

I suppose i could go to the breakers but i need to find a breakers with a sierra and that aint as rusty as mine are lol.

Good idea though, ill give it some thought.

[Ebonycossie4x4]

Right well i better resurect this thread as work is starting to commence.

After yet another deal falling through its time to rebuild the engine for definate.

First and foremost i need to thank LambChop, I have bought near enough new pistons with new rings in fantastic condition in exactly the right size for Ł200.

The bottom end is 0.08 too large on cylinder 3 so block will be bored to 0.5 so i have bought .5 pistons.

Just bought multi layer head gasket and gasket kits, I dont know wether to go for the stud kit or standard head bolts. im going to be running about 26Psi and to be honest the car will probably be sold not to long after knowing me lol.

I have my escort turbo too so this thread will be slow going. I will update with pics as the bits arrive.

Im going to be running standard cams, T34 turbo, Standard compression, greens etc

if i wanted to max the turbo say 30psi I cant do that on standard head bolts can I?

Would i need light blues too?

Sorry about all the questions, Hopefully you guys can help as this is my first engine build.

Will update with pics soon.

[AquariousRS]

I belive NMS run standard head bolts on majority of there builds. Been quite a few debates on it on here if you do a search about it

[Glenn.]

Top work mate.Im happy your sorting out and not just breaking the car.

[Ebonycossie4x4]

Right well i really need to start getting on with this. Block is in getting machined to take the .5 oversize pistons.

Crank is also being balanced and cleaned as oil ways are full of orange shit that some idiot had put the rocker cover on with.

Spec is going to be very light mods as i just want a safe and reliable stage3 +

So

0.5 oversize genuine mahle pistons.
.5 Bottom end rebore
T34 Turbo
Standard Balanced Crank (no need to regrind)
ACL race Bearings
Standard Genuine Ford Head Bolts
WRC Multi layer headgasket
Arp Rod Bolts
Gp A timing Belt.
Head stripped and valve stem seals changed with valve guides checked and replaced as neccesary.

Me and a friend are doing this (im being brave) or tight one or the other, so wish me luck.

Have got all new gaskets and i am going to try and clean and paint all items before going back into car.

I expect it to be all done within a month.

I just hope i dont live to regret this. Curently the car owes me less than what it would sell for so its all good.

Still need to make the decision on keeping when its all done, I am looking forward to driving the first engine ive helped build....

At least i know when ive done it myself i atleast wont fill the sump up with half a rubber glove and orange mastic.

[Glenn.]

Well good luck mate.I hope after fitting all the seals that you dont have oil leaks.

[Ebonycossie4x4]

should be ok, doing it with a good family friend thats probably built 50 engines, Its his second cosworth engine and hes just helping me along when i get stuck.

[andy escos]

good luck with your engine build ,your car looks well nice on them rims

[Ebonycossie4x4]

Bottom end is now built and ready, As usual with me as we started to remove the valves from the head every other one we took out had knackered valve guides.

Loads of oil in there and the stem seals are fooked too. I have new stem seals but the head has now gone back to the machine shop to have the valve guides.

More money lol.

hope fully it will still go back in this weekend. Will have some pics when i get my camera back!

[Glenn.]

Good work mate i hope its all finished soon.

[Ebonycossie4x4]

Well i got the engine back wednesday and ive been painting bits all week and bolting bits back to it.

Today i got it in there. Result.

Not running yet as i snapped the power steering pipe so i have one coming from a guy on here by wednesday.

The aftermarket fan wiring is here and its fantastic quality, will tidy up the bay so much.

Engine being built up, Its tidyer now but unfortunately im no bufty lol.



Engine being rolled in, So much easier this way, i will never take a cossie engine out from the top again!



And in the bay



Just the rad cooler power steering pipe and a few other pipes, Cable on starter motor battery on JOB DONE!

Run in MOT and on PH i think lol. What an effort...

Washed it too just love the colour when its clean.

Im so proud of being able to do it and not pay thousands to someone else.

This is a full rebuild with all new valve guides standard crank no need for grind Mint 500 mile pistons race bearings and new everything that was needed for well under 1K.

Lets just hope its fine and runs as nice as i hope it will lol.

Cheers Guys

[jonnyrsturbo]

looks nice that matey

[cossimc]

Originally Posted by timster

It is the correct gasket but when you refit put some sealer either side of the seals to hold them in place when re-fitting the rocker cover.I know they're torx on them can't remember the size though.Haven't done a cossie head gasket for over five years.Hopefully someone on here will help you out

its a spline not a torx bit m8t