bit

Hi Everyone,
Well. Where to begin….
I’m in Vancouver Canada (Surrey to be precise) and like everyone here, I’m a car nut. My first love in Motorsport is Porsche. Whether they are the best at whatever or not, I love them for what they are and what joy and excitement they have given to me in my life.

Few years back I bought a 1980 911SC that I restored, it is now a garage queen. If you are interested, that story is located here:

So I bought a Porsche (very long) opinions please
My Winter Projects Update - like usual, long
My Winter Projects Update 2 (long again)
My Winter Projects Update 3 (long again, but it's almost over)
The never ending Winter project project. Now very depressed.
DUDES!! My Winter projects are DONE!! WOOHOO!!
Frequency Valve and Lambda computer testing. Please Help.
1980 911SC Distributor Recurve Results
It was an awsome summer, but now it's time to update!
2005 Winter Projects update
Rear Reflector restoration
2005 Winter projects done - Suspension and Brakes w/ Results (long)
Window switches and relays
Fixed the annoying swaybar squeek!!

So for a little while I was happy. The old 3 litre NA engine in such light weight car was perfect!

But I soon realized that I like to tinker and drove it less and less. Always dreaming of new things I can do to it, but it is perfect as it is.

I was in the UK in Summer 2006 (I’m originally from ‘Brum). My brother-in-law (Aj) is a car trader in Walsall and he was always yapping on about Cosworth this and that and all the great cars that have moved through his hands. Now I have always hard of Cossies, but you see out here, we have big V8 Fords like Mustangs etc….no Cossies. I've always been a Ford Fan!

So when I arrived to his house from Manchester airport and just settled in, it was about 11pm now, warm night. He showed me to (my future) Cossie.
Get in, you drive mate he sed with a smile.

Jetlagged and all, I started up the old clunker and rolled down the lane to the M5 motorway and merged on. G’won, giver he sez, and I stepped on it, I was in second gear….

I nearly peed and quickly let off, my GOD!!! I looked at Aj, and he was howling!!!!!

So shift to 3rd, all way to red, Shift to 4th all way to red, Shift to 5th , 120mph and climbing with no effort. No one on the freeway. It was one of those special driving moments. Into B’Ham, skidding all the round-abouts, and finally making it back home by 3am, full take of gas almost gone.

In the dark night, the turbo was glowing red hot J, Aj has never seen that before. Let her run idle for a few minutes to cool off. Start drink beer and talk about this CAR!!! My GOD this CAR!!!


Long story short. I bought it for 2500 UK pounds. The old girl needed a fair amount of work. But it looked like all the bits and bobs that it needed were there. Stage 3 Modified Sapphire Cossie. Here is what it looked like when I met her. She was going to need a lot of work.







So zoom ahead about 18 months, I finally managed to import it from UK to Vancouver (shipped from South Hampton to Tacoma Washington, then driven to Vancouver). Total Cost, $5000 Canadian. So pretty much I’m into the car for $9500, not to bad me thinks, but this is where the fun starts……..or does it?

Having restored a car before, I know exactly how shitty of a job it truly is. While I was in UK, Paul from PJ Motorsports fully live mapped my car, it was running just awesome when I was in the UK, here in Vancouver, not so much. I met a fellow named Daz Jones (yes he is the same rip off guy from Tamworth I think) who started a Cossie business in Vancouver. Strange I thought, I must have been his only customer, but he had a few EsCos and Sierra and Saph’s.

Anyway, he tried to get my car to pass Aircare (emissions) with no success. He sold me a whole much of parts and stuff that I eventually will need and to pretty things up, but he just whipped it in and did not really care about his install. It was a mess. Car ran like shit, and then Daz went bankrupt. From what I hear it is a good thing I got my car back!! Anyway, he was the niciest guy and I think his heart was truly in the right place, just his finances not so much. I did get off him a 200 block, blue boost hoses and cam cover. And tonnes of other bits and bobs... I spent about $7500 Canadian with this fellow.

Here is what it looked like after Daz. He found a hairline crack in the original 205 block, so now I have a 200 block. This is about Jan 2009.





To Be continued...

bit

So, after feeling much burned. I decided it was about time I rip into this damn car. And do the cleanup and recovery it truly requires! Started the project in March and finished by the end of April 2010.

Below are Before Pics





















Below are During Pics

bit

Below are details of what I have!!

Cossie Engine Details
Blue Cam Cover
200 YB Block - low Miles (6K)
Bosch 803 Green Injectors
3 Bar Map Sensor
T34 Hybrid Turbo
-31 Actuator
RS500 Intercooler
Baily Pistoned Dump Valve
Blue Samco Boost Hose Kit
K&N Air Filter
Koni Front and Rear Shocks
Scorpion 3" Exhaust
Remapped L6 ECU Stage 3 24 PSI
Forge Engine Breather canister/system
Aluminum Rad Resovoir and Swirl Pot
Slotted front/rear brake disks
Koni Adjustable front and rear Shocks
Ford Racing Guages - Boost - VDC - Oil Pressure
White dash dials

The following items were completed at the 131000 mile mark on the Odometer

complete remove disassemble and reassemble/retorque engine and re-install
-replace all worn bolts (& missing bolts Thanks DAZ)
remove engine bay firewall carpet and clean rear firewall
sand blast and paint all engine metals
break and repair main power steering pipe at banjo fitting as it was rusted seized during removal
-pipe was repaired by welding the tear shut
break and repair 3 bar map sensor nub by bumping into it on removal
-nub was repaired by inserting metal pipe from needle valve as a metal anchor
-then JB Weld the nub back on with needle is an anchor in the center
complete top end gasket & seals installed
replaced all valve stem seals kit
complete bottom end gasket kit, oilpan gaskets and rear main seal kit
power stearing pump disassemble paint clean and rebuild
alternator rebuild, clean and repaint - brushes checked ok
starter rebuild, clean and repaint - brushes checked ok
Complete disassemble and rebuild and repaint intake manifold
-clean all internals and re-gasket manifold
Group A cometic head gasket installed
fuel injectors rebuilt with new filters/internals and flow tested
new 6 paddle alcon clutch disc installed
-new alcon pressure plate
-new alcon thrust bearing
Resurface flywheel
new spark plugs
new spark plug cables
new dist/rotor
new K&N Filter
create Boost solenoid mount plate
repair Boost solenoid (Amal Vlave) damaged screw hole
replaced Radiator temperature switch
replaced thermostat and gasket
Rebuild and repair dual front fans
-sandblast and remove rust and paint bare metals
-repair brushes and melted braided wire on one fan that would not work - fan ok now
-repair fan wiring harness that was melted - both fans now work
replaced all hose clamps/jubilee fittings
repair rust and prime/paint engine bay with matching color
repair engine bay wiring harness and connectors that were damaged
repair and remove rust from rear firewall panel
-installed mesh replacement for removed area
replaced oil pressure gauge pipe
brake rebuild front brake calipers
-replace all rubbers 4003 kit
-sandblast and paint calipers
-remove and replace seized bleed valves
-replaced brake pads
brake rebuild rear brake calipers
-replace all rubbers 4303 kit
-sandblast and paint calipers
-remove and replace bleed valves
-replaced brake pads
Complete bleed brakes DOT4
Flush and install 50/50 anti-freeze
Flush and install 0W40 Mobile1 and new filter
Flush and install Power Steering fluid
Break stock rear differential / Replaced rear differentail with used unit
New timing belt and belt tensioner
New Alternator belts
New power steering belt
Repaired and adjusted sun roof
Replaced damaged driver side electric mirror
Replaced all door panels

And that is about it.

Notable Events
-Broke the 3 bar map sensor (repair listed above)
-Broke and repaired main power steering pipe.
-Blew my rear diff. Got a new (used) one in 5 days from the UK for 250 pounts incl shipping (thanks Aj!!).

Things still left to do.
AEM Gauge Boost Controller
AEM Alcohol/Water Injection Kit
Interior clean up
-remove seats and rear rust/damage on floor boards
-paint/repair front and rear leather damage
-relocate gauges to dash level 2
-reinstall center dash vent
-install new stereo in dash level 3
-remove and re-glue headliner
-install new speakers


After all the above, the car ran great for about 1000 mile then it started to misfire on boost (I’m doing about 24 psi). I adjusted the spark gap to .65, now the car is PERFECT.

I also discovered this car pisses thru the 0W40 oil. So now I am trying the 15W50 Mobile1. I'll let you know how that goes.

Anyway. Enough for now. Comments?

.Steven
1980 Porsche 911SC
1989 Ford Sierra Sapphire RS Cosworth

bit

What my blown diff looked like.
I was driving pretty hard on damp roads, hit a dry spot while shifting to second and got good traction and detroyed the rear diff. I think I'll weld it shut for some good old hooliganism. Just the damn thing is a bitch to re-install!!


My Brother in law found me a Diff in the UK for 150 Quid, plus it cost 100 quid to courier to here. Took 5 days.









.Steven

bit

I rebuilt both front and rear brakes.
The Bigg Redd rebuild kits are great!
.S

bit

Oh and I drive this thing every day now. It has been one AWESOME Summer!!!
I do not regret getting this car at all!!! 330BHP on tap all day long.
Things I'm sure you all knew already.

.S

focusrrx87

awsome dedication

top work!

evo-vlc

Good job, now if this beautiful engine.

The Crocodile Hunter

Nice story, what does everyone back in canada think of it?

Do many even know what it is?

Brian

iTrader: (2)

Awesome mate


Brian

R4N SS

iTrader: (6)

love it - got loads of family in vancouver and they all own farms

Surrey is where its at .

Bet everyone looks at that think what the fook is that?

If I ever move to Canada I WILL have to get a cossie out there - you will destroy almost all of the yank stuff

155lee

iTrader: (10)

was it hard to get it into canada?i thought cars had to be 25 years old to get in?and what about if you wanted to take it to america,would that be possible?

bit

Hi Guys,
Thanks for your comments. Yah no one out here knows what it is. "If" I gets noticed, all they first see is that I'm sitting on the wrong side. They hear me coming but no one sees me, they all look right past. Heh heh....exactly the effect I want. It is a very professional looking car me thinks. The hood grills and red brakes are the subtle give-aways. Certainly a wolf in sheeps clothing.

The car needed to be over 15 years old to be exempt from regulations and import rules whatever. Just needs to be road safety inspected and it needs to pass Aircare emissions and then that's about it, you can insure the car. This area is abundant with Nissan Skylines and Mitsubishi Delica's from Japan!

I contracted a company out here called All Cargo Express. For about $3900, they handled the complete shipment from the UK to me. It left UK on about mid October 2008 and arrived on my BIRTHDAY in December!!!! 6 Weeks. Long trip through the Panama Canal!!

The Alpine stereo was missing (the changer was still under the seat) and it looked like someone tried to hotwire the car. the whole plastic casing that surrounds the key and steering console is all busted and the wires were pulled out. ACE had to get it repaired (an extra $300) to fix the wiring so they could start the car to drive from Tacoma shipyard iin USA to BC. What a fiasco. Then it cost about $600 ar the border for tax/duties etc..

I still could not belive it arrived on my birthday. The weather was crap and cold/snowing etc, but I didn't care, I insured it on a two week permit and drove it around. On the second day, I drove over a pothole and got a flat on the front right tire. I tried to install the spare, would not fit. Installed the spare on the rear and move the back tire to the front, in fooking 0 degreez weather. sigh....

Then there was the fiasco of getting the wrong oversized tire as the car (as I found out later) had the wrong sized tires installed (225/45 R16). I managed to find one to match the same size as the others. and drove like this for a bit.

I have now corrected all my tires and have installed now BFGoodrich g-Force T/A KDW 225/40 R16 all around. Awesome Tires!!

http://www.bfgoodrichtires.com/tire-...-t-a-kdw-tires


Cheers.
.Steven

.Ross.

iTrader: (2)

Good work mate.

I never seen any Cossies when I lived out there ... Only Blown V8's ..

P.S: Should'a' got the VAN 2010 Plates mate ...

COLEYST200

iTrader: (3)

keep up the good work mate

TieMyShoe

woohoo!! another local YB!!!

thebronze

Nice ride...Where are you located?? I know of 2 other 4drs and a 3 dr...

bit

I'm located by Bear Creek park in Surrey. I have seen a few non-running Saphs and 3Doors. I have yet to see another YB running on the road out here. I feel pretty alone. I'll be putting Cossie to sleep for the Winter on Oct 20th when insurance expires. Bronze you need to get me in touch with the other Cossie owners you know, we can make a BC owners club!!
.Steven

Cossy Mike

iTrader: (4)

scottyrs

iTrader: (1)

weldone mate alot of hard work gone into that looks nice now!

COCHYN

3-2 man, Luongo rocks

DazC

iTrader: (1)

Get a Quaife ATB in that diff and that will remove the weak planet gears. That moves the weak spot to the crown wheel and pinion then but at stage 3 you'd have to be driving like an utter utter tool all the time to break it.

tejy

iTrader: (1)

Very nice job so far mate, when you gotta have one.. you gotta have one ..Feel the pain of changing your flat tyre then having to take the back one off, it's happened to me more than once before lol! Anyway keep the updates coming!!

darrenb16two

Awesome mate, proper stunning looking car with some ace work youve done on it

jason_nike

Nice work there mate, very nice
Now you can enjoy the car

0150carmac

looking good enjoy

smila

iTrader: (1)

No updates since 2010 anything else been done?