chodjinn

I don't often post on this forum as I'm not a ford owner, but I have followed this for a while. The rear rad work is brilliant and your work on the carbon cover is amazing for a first timer, so much so you've convinced me to have a go eventually!

cossiedevil

The cross bar is able to stay as is ,the carbon was a bit easier than i thought as i expected to at least have to do it a few times but came out very well for my first time and i had my shed at 20 degrees that was the only heat but have to say that the laminated epoxy resin when mixed to the spec sheet, what was left over in the pot you would think it was going on fire with the heat and smoke leaving it when going off scary sh*t

cossiedevil

Some wee jobs done,Someone did post way back to what was i going to do with the o.e shock gussets as the wrc cars had different ones welded in so i made these myself,

james kiely

iTrader: (5)

It's going to be epic David

cossiedevil

Thanks James

cossiedevil

welding up all the holes in the front wheel arch's,

reese646

Looking Great David, Really need to get some more done on mine, its looking sad as its been sat for nearly a year since I last touched it.

Now your back on it if your interested I happened to get access to one of the last Ford works built WRC cars and have around 100 pictures of the bare shell inside and out and the underside, let me know if you fancy them as theres quite a few little bits that you wouldn't see otherwise.

Looking great and good progress mate, the carbon work looks fab, did you make your own engine mounts by the way or order them as I fancy making my own, catch you soon and let me know on the pics

cossiedevil

Thanks fella,these cars can eat up time i have been on and off it and nearly two years sitting till late,as other things needed my time and got the car in may 2011,thanks for the offer on the pics progress is going very well in fact better than i had thought maybe it paid off to be away from it for awhile engine mounts are genuine gordon vincent made that i got from dewitts

cossiedevil

Made up strap's to hold the fuel cell in place to match in with hafsengen style,

whizzisat114

iTrader: (2)

Going to be one hell of a car when it's finished
The attention to detail is off the scale

COSSIEGAZ

When you had two pieces of carbon over lapping was there much of a ridge cause of thickness of material? Did you sand it flush or when you rolled it to get rid of air bubbles did it flatten it?

cossiedevil

Thanks fella

the way i did it was Clear laminated coat first left 3 hours to go tacky then lay down first layer of carbon pushed down by hand and then paddle rolled,and then half hour between each layer put on after each paddle rolled total layers used 6 left over night and pulled out from the mould next day

COSSIEGAZ

Your doing an amazing job mate and look forward to one day seeing it in the flesh. Would you recommend people to have a go at carbon fibre now you have tried it? How much more body prep do you think you have before you paint it again?

cossiedevil

Thanks ,as for the carbon fiber I have work with fiberglass so had a wee heads up but I would say if your able and watch a few vidz you can do it for me mine was a very big area and its not 100% but will have to do but in saying that I have also bought carbon parts and they where not 100% air bubbles in the clear coat etc so I reckon it take a good man or company setup to do it right,as for the shell all that is left is to weld in my mounting nuts for the six point harness and paint then

frayz

I love checking back in on this. Stians car was and still is the greatest escort dossier ever built IMO. Superb that you're attempting to recreate it in such detail. Really makes its special. Look forward to seeing more.

cossiedevil

well guys Shell work is nearly finished its took soon time alot of cutting and welding and totally more than i thought i was able to do but the shell is nearly to full wrc spec ,

alot has changed to what is was when i got it,

reese646

Very impressive mate, been worth the wait. I bet like me you'll be happy to finally stop telling people "when the shells done its just bolt it together" lol it just takes forever to get the shell done

How much of the bolt on stuff are you missing, I think your probably not far off.

reese646

Meant to ask are you going for the big front diff with it been right hand drive, as I have actually seen a group A car that had the large diff and was right hand drive, he had a knuckle setup that transferred the steering across to the passenger side, so it is possible.

frayz

Proper shells take ages. Mines been in prep since the start of February.
Cossie shells looking amazing.

cossie martin

Awesome Project!!

Focosmitch

iTrader: (1)

Awesome! Looking forward to seeing it in paint!!

fezzajsy

iTrader: (9)

Looking good

Adam-M

You still messing with imprezas and hankering for a cossie or have you made the switch Yet mate? Followed your build thread on scooby bet I could well tell your were dying to get back into a cossie lol

cossiedevil

Thanks fella glad to see it nearly all done and not bad as all done with no help at all missing very little bolt on parts just cant wait to get to that stage,Also diff will i hope be mainly issue free,

Thanks fella long time coming,Also you scooby is savage and not a cheap job been done to the shell
Thanks
Thanks

cossiedevil

Some more new goodies freshly made supplied by dewitts was worth the wait,So just have to build the uprights up,

frayz

Still got it, and yes its in a million pieces again.
No there still wasnt anything wrong with it, and yes im an idiot! lol

zetaboostboy522bhp

Nice work and iam so glad to seeing it built up.
Can I ask how much the drive flanges , bolts and sleeves are pm me if you like

Cheers paul

cossiedevil

Thanks Paul im glad myself to see it coming along
Flanges,bolts and sleeves from dewitts where €2214,the euro to sterling is very bad but put it in at .68 comes to Ł1506 paid for these back end of February they had non in stock so had to wait on them being made only got them 2 weeks ago,

cossiedevil

Upright are complete done all the press work on them,

my workmate for the job,

whizzisat114

iTrader: (2)

Very nice �� ��

thielt1

I love those wheels, glad to see you working on this again!

COSSIEGAZ

Are the wheels 18s or 19s? I thought stian ran 19s or was it his white wheels that were 19s

cossiedevil

Thanks lads

Wheel's are 18" same wheel as what stian got with the rolling shell and used at the beginning,19" rims where speedline's 2014 sc magnesium rims the white ones, stian sold these and where on a escos in Sweden then they where for sale pm the guy but never got any further than that i was emailed about another set that where fitted on a rs200 that stian was working on but rims and car was bought by ken block,And have emailed and contacted speedline to see could i get new set's made but they where not interested,So the sparco comodora reps will have to stay and as its a pre crash first build rep of hafsengen cars these are the rims he ran on it first outing for gatebil

COSSIEGAZ

Cool I like these wheels think it had a more aggressive stance to it but the speedlines were nice. Are you copying his dash and control panel or slightly changing it? If it's gonna be a true rep then it would have to be the same even if all the buttons didn't work for what they were meant too? Interested what your planning to do and as always look forward to the progress. Reminds me I have the DVD of his car so will have to watch it for the 90th time lol

Cossiesteve

Being new to pf i have sat and read the entire build thread to date and i must say the car is a work of art, and to be fair I've always had a soft spot for stains car from all those years back, so seeing someone replicate an iconic car in such great detail is awesome, look forward to following this build mate

Glenn_

iTrader: (1)

Cool hubs them. Nice wheels too.

cossiedevil

Thanks very much Guys

Few pics of my rear rad setup as carbon surround cut to allow heating pipes run out ,

COSSIEGAZ

( just asking) was there no way to get the fitting for the surround so you had a pipe from rad to surround then surround to engine? Just thinking if you could of kept it fully sealed? It's looking good thou mate.

cossiedevil

it would be very hard as the rad takes screw on fittings not push,so would be alot of work to make it sealed, but it will be done the same as hafsengen where the cut out will get sealed up with heat tape,so no heat are air to get into the cab,

M K

iTrader: (9)

Excellent work my friend