James_RScos

Well!!!!!!!!!!!!!
Im bored of H380 TBV!

https://passionford.com/forum/restor...or-2010-a.html

So im starting work on my new toy H686 ODA, its another Sapphire Cosworth! YES I DO LOVE THEM.
The plan is fast road/ track, cossie power.
It a 4x4 shell but im going to run it RWD,

I have bags full of ideas for it but the main aim is :
Rally styling and prep.
Striped out stitch welded, cage
arches rolled and flared like rally sapphires
polly brushed and coilovers
polly windows
two bucket seats + harniesses
escort cosworth monte rims 16"
colour scheme frozen white and piano black on the plastics
running in 2wd form with a mix and full cossie setup IE suspenion and running gear!
Pic to follow!

James_RScos

Car as it stands full rolling but striped out ready for prepping.

Door are getting cut out for lightness, will have some nice covers to go over them + polly windows with sliders

Engine bay stripped out ready for prep!

Inside stripped out ready to remove sound deadening

Bucket seat

Thats all for now!!
Iv got some engine bits coming this week!!
2L pinto engine
205 bottom end
205 pinto efi + engine loom and ecu
type 9 gearbox!!
watch this space!!
James.

Viper_

You can't fool me James - that IS H380 TBV, you just tinkered and messed with it so much, not knowing when to stop, went too far and made a right mess of it (think Father Ted when he tries to tap that small dent out LOL!)

Only joking bud - I can visualise the car from what you've said in the plans for it and it sounds superb mate. Best of luck and look forward to seeing it progress. If your other Saph is anything to go my it'll be fantastic

James_RScos

Cheers Mark!!!

Moonstone Mo

iTrader: (3)

Looks like you have your work cut out james,but fair play mate.

will be keeping an eye on this.

James_RScos

.......

Brettski mk2

iTrader: (3)

Welcome to the slipply slop in to the money pit

Tell me more about the "arches rolled and flared like rally sapphires" got any pics

I'm going to national day mite bump in to you
brett

James_RScos

U like?

Im not sure weather its more a tarmac spec thing!! a friend of mine has an EX RED shell and that has the same done to the arches!!

i must looks hard as FOOOOOOK!!!

James.

Kverna

iTrader: (1)

Good luck on the build mate

James_RScos

Update.
Sorry about the picture quality i will start using my camrera again, but its so easy to pick up the iphone HA!
Saturday was a great day for playing with the shell, my mate Mark popped down and wanted to help and asked if he could remove the sound deadening HAHA so i said crack on know what a crap job it is to do, WELL three hours later WELL DONE Mark is all im saying!




I attended to finishing off the cutting out of the door and removing the glass.


The doors are cut out rough for now, when i remove them for painting i will put the side by side and profile them so they are cut out the same and look right!!
Plan for the doors is cleaned inside and painted white like the rest of the car then i will run a rubber bead round the edges to smarten them up, and poly windows.
I also started smoothing the back bumper with Fibre filler, so i roughed all the areas to be filled and started filling and sanding, next will be a skim of filler then stopper over that ready for paint.
Thats all for now.
James.

Moonstone Mo

iTrader: (3)

How was concours this year james.

James_RScos

Hi Mate,

Hope your well?

Iv posted an update on that thread!

James.

James_RScos

Update time!
This weekend i did alot of body work, and collected some parts!
So lots of smoothing going on!
Roof strippes





Rear quarter plastics


Panels in Stopper



Started flatting the car down



Bumper being smoothed

Bonnet vents being rubbed down

On Sunday i collected some 2wd rear end components
2wd LSD 7 1/2" diff and drive shafts

2wd beam

Hubs and Flanges

Diff opened and teeth checked, all good

Drive shafts stripped down in bits ready to be broken down more fdor refurb

Battery tray cut out

Where the tray was, battery will be in rear of car now behind passenger

All scuttle wall brackets removed and bolt studs and clips removed!

All studs and brackets removed from the insdie of the car too

Got a new DA this morning as the other one was playing up so will finished flatting the car down!!
Also removed more waxoil from inside the doors
Ordered some Polycarbinate sheets to make my side windows out of yes that plastic windows
More to come later this week.
James.

Moonstone Mo

iTrader: (3)

no messing about james

cozzie123

top work James! you certainly dont mess about

scottyrs

iTrader: (1)

good progress there mate good luck with it

James_RScos

Cheers all

Update time!!
I had the 7th - 10th off work and all four days where hard on the project.
Lots done, i will let the photos do most the talking.
We have Polycarbinate windows, made them myself, easy as....



Finished flatting the car in 400 ready for paint

Bonnet not far off

Other side little more work to do

Boot prepped but a little work to do around the spoiler holes

Boot lid off and boot cleaned out ready for de-seem sealering

Started cleaning the engine bay up and smoothing it off

Front Screen out

Dash keyed up

My first go at welding, not bad i think!! slam panel getting smoothed


Petrol Filler cap plated and smoothed(first skim)

Bumper smoothing


Slam panel smoothing

Battery tray welded up ready for grinding

Dash skimmed with stopper

Started cleaing the seem sealer off the seems for stitch welding

More to come soon, James.

Twins

iTrader: (18)

Fantastic

RS-Stian

iTrader: (1)

Looking very good James

James_RScos

Cheers All,

Just thougth people maybe interested in my thinking and inspiration behind this project!
Well most of them are restless nights and sweet dreams, but the other 80% is my love of Fords Sierra's of course, and also my love of Rallying and Sierra's mixed into the bag.
Couple of famous Ford Sapphire Cosworth Rally cars for you all.

The Q8 Car



The Carglass Car







On the second photo of the carglass car, notice the front arch is rolled and flared, that is what i would like to achieve with mine.
These are insane cars and my wildest dreams, my inspirations i love to just look at rally cars that have been build properly and by Engineers, some of the details and the engineering that goes into the cars is mind blowing, Ford are good but Audi are proberbly one of the best i would say!

For anyone interested this video is very informative about Fords production of the Q8 and Autoglass cars in the 1990 season and there driver line ups with some interesting info!

YouTube - Ford Works Rally Team 1990....[/url]

James.

Lo@der

iTrader: (8)

Now that is stunning , very clean yet purposeful.

James_RScos

UPDATE TIME!
Ok borrowed an arch roller this weekend, and iv master the dark art of arch rolling and flaring.
Back arch wearing an Escort Cosworth Monte Carlo Alloy

Front


Welded all the small holes up in the front inner arch and ground back

Same on Battery tray but this may get cut out and a new bit of metal welded in yet!
My mate Lee continued removing the Seam Sealer bloody stuff!


Gunked and jet washed me block!

More soon :+

jim_robson

Anymore updates??

Brettski mk2

iTrader: (3)

Going nicey James.Just takes time and an't much fun is it Soon be done and start getting it back together

AJC

iTrader: (6)

excellent work

Steve the Plumber

iTrader: (11)

Great project and keep up the good work!

fezzajsy

iTrader: (9)

Glenn_

iTrader: (1)

Wow top project.I think you should do your car like the Q8 one in then pic.It will look mint.I like the idea of the flared arches.

James_RScos

Right!
This projects been moving forward, just havent had time to write it up sadly.
My workshop has had a bit of a cleanup and a lick of paint (white) so everythings looking clean again
Ok, first of all, my roll cage is on order from Rollcentre in cambrigde

That is the design iv gone for with one little mod! the main hoop has a horizontal bar in it, iv gone for a diagnol.
Its a full weld in 8 point cage and comes with all the mounting plates for the floor.
Hoping it will be here in the next couple of weeks.
The porject its self is coming together, the shell is now fully stitch welded in the cockpit, engine bay and boot, me and some mates that also have project have just made a spit between us at a cost of Ł40, its made from 40mm box so very strong.



On the car, Xmas day i got bored and felt like crap layed around the house, so i popped down the workshop for a couple of hours and cut my boot floor out as you do ha!

Couple of repairs around that area, i then made the new flat boot floor.

This is placed in and spot welded.

The spot where half an inch from the edge and 2 inches with an 8mm drill bit used to make the holes, once the floor had cooled i primed the bare metal and ran seam sealer round the edge then primed again once dry.
Iv started work on part of the firewall, this is the pacel shelf part.

The hindges for the boot come up into this area so some small recesses where made for the hindges to go in, i also had a problem that the hindges bolted on from the top so if i ever needed to remove them i would have to start taking all my firewall apart! so i reversed the captive nut to the top and the hindges now bolt on from below.


These have since been ground down and a small smeer of stopper ran round the edges, just need to sand it back.
I have cut out my slam panel, the ends have now got a plate welded on and smoothed, just need to get a bit of box to fill it and fit it up, for easy engine removal!
My battery try has been cut out again as i wanted happy with it at all!
Finished all the filling!
I hope to be having a carbon fibre roof made up so i can cut my sunroof and metal roof cut, this will also help the centre of gravity, and bring the side to side pitch of the car right down to a minimum.
Front doors are off and being de-greased in the final stages before paint.
Floor has been repaired where holes where and ground back.
Next big step is to turn the car on the spit and clean the underneath of and fix anything untoward.
More updates soon, its getting interresting now
James.

maxest

iTrader: (1)

Very cool project,, and lots of work gone into it!

fezzajsy

iTrader: (9)

James_RScos

Little update:

last night i visited one of my inspirational friends!

We talked at lengh on the suspension setup of my car, the setup has been choosen.

4 point linked rear end with diff frame.
Ajustable front end with a single link from the ARB mounts.

So along the lines of WRC spec.

This is going to be fun

Working on the project this sunday, so updates monday i hope.

Cheers all.

James_RScos

Right!
Update time, wasnt an overly active weekend on the road, just a nice steady pace!
My mate Mr Ward was on hand to help out, cheers mate.
Did a bit of sanding of filter in the engine bay and on the firewall shelf.




Still a little more work to do there!
Made a strenghening bar to support the firewall.

Started cutting out the main part of the firewall, still need to fine tune the shape at the bottom, then when the cage is installed i will cut the firewall in half, once i have the measurements for where the rear stays are coming through from the rear struts to the main hoop, this will then allow me to cut out half moons on the firewall and fit it around the cage perfectly, that why there is a massive overhang at the top of the firewall, so i can overlap the two peaces of the firewall and pop rivet them together.

View from the side of the firewall, i have left the holes at the side for running fuel lines and loom through.

Started cleaning up the insdie of the door for painting and also matching the shape of the cut out so they look the same.
Thats all for this week, going to try and measure car up for the spit tonight and make the supports to clap to the car, next weekend im hoping to have the car on its side!
James.

Brian

iTrader: (2)

Brian

jason_nike

Fantastic matey, plenty of neat work done there

nuttynil

iTrader: (3)

well done like this project looks fun..

Brettski mk2

iTrader: (3)

You'll be overtaking me soon!!! have you finished all the seam welding now.

James_RScos

Hi Brett,

Not yet mate, inside, engine bay, boot is done, just waiting to get the spit finished and down to my unit then i will do the underside, then it will be finished.

James.

Steve the Plumber

iTrader: (11)

Looking good

davy 6457

you dont happen to know where your friend with the carglass car got his light pod at?