545 bhp Radiant Red Sapphire Cosworth
22-05-2011, 08:09 PM
#1
545 bhp Radiant Red Sapphire Cosworth
Ive had the car for nearly a year now so i suppose its about time i did a bit of a project thread 
I picked the car up from Danny@Enhanced Performance towards the end of summer last year, the car looked a bit off a mess to be fair, but mechanically and body wise it was spot on, just needing a set of wheels and front brakes, a damn good polish, and the interior tidying up.
this was how she looked when i first went to view it.
i think one of the wheels was bent so Danny sorted out a set of lattice wheels to drive it home on, didnt take any pics as it looked poo
Before i had even picked the car up i had bought a set of 17x8 Comp Mo's off Shorty, and a set of Kuhmo Ku31's
I never really liked the wheels in white, mainly because i had to clean so often So i had them powdercoated in dark grey.
Also the front brakes were awfull, the discs were warped, the pistons were siezed to start with on one side, and it was just dangerous. So i Picked up a set of Fiat coupe turbo brembo calipers, New focus RS EBC plain discs and Mintex pads.
Made a set of brackets up using a piece of 5/8" thick alluminium, and bolted them all up, the brackets werent perfect and ended up with the caliper sat about 3mm too far out, although it worked perfectly so i left it.
Then the Girlfriend got us a Stunning new steering wheel for christmas to replace that awfull Momo one
At the same time i retrimmed my headlining and fitted my new leather interior, the original cloth seats were ok but the door cards were tatty.
I drove the car for a few months without really changing much, just sorting out little bits and bobs and getting bored with 300bhp
I had the car on a local hub dyno at a bit of a meet, it made 293bhp and about 320 ft/lb before the clutch let go would have probably just pipped 300bhp
So i dropped the gearbox, had the flywheel skimmed and fitted an AP 6 paddle, at the same time i picked up another set of new wheels off Martin@Reyland and had them powder coated. When i came to fit them it turned out my previous slight cock up with the caliper brackets meant the wheels wouldnt fit
i ended up having to remake the brackets and run 6mm spacers on the front to clear them making the front ET29. I put a set of 5mm spacers on the rear too to bring them to ET30.
First show for the car then, Modified Live at oulton park with Cheshire RSOC, Girlfriends brother Chris (slammedorion) gave the car a quick Mop and polish the night before
The car was running well, but using a bit too much for my liking, Valve stem Oil seals/guides i believe. i thought about rebuilding the top end but it would still be on a 90kish 205 block and 2wd pistons
So the other weekend, i headed up to aberdeen with my brother, in my mums little clio as it does over 50mpg, and picked this up
One of Yum's old engines Spec is:
Small turbo Escort 200 block
ARP long stud and nut kit
WRC 4 layer SS head gasket
Touring Car spares Gated sump
7.6-1 Comp Ratio
ARP big end bolts
ported & flowed Cyl Head
MA spec inlet Cam
Kent Vernier pullys
Double Valve springs
Small turbo Inlet manifold plenum and throttle body
Rochester 1000cc injectors
Turbo Technics T38 turbo
Made 466bhp a few years ago
So this weekend, after a couple of weeks collecting up parts, I got the new engine in.
Started off looking like this:
3 hours later:
Then gave the engine bay a soaking with TFR and a scrub with a paintbrush
Whipped the sump off to drill and tap for my Oil temperature gauge
Touring cars gated sump, very nice
spent a few hours swapping stuff over last night, and then this morning a mate popped round and gave us a lift:
Still not liking the yellow inlet I will get it up and running then spend a day sorting bits like that.
Hopefully this week i can get it all connected up, and then get it mapped and back on the road
I picked the car up from Danny@Enhanced Performance towards the end of summer last year, the car looked a bit off a mess to be fair, but mechanically and body wise it was spot on, just needing a set of wheels and front brakes, a damn good polish, and the interior tidying up.
this was how she looked when i first went to view it.
i think one of the wheels was bent so Danny sorted out a set of lattice wheels to drive it home on, didnt take any pics as it looked poo
Before i had even picked the car up i had bought a set of 17x8 Comp Mo's off Shorty, and a set of Kuhmo Ku31's
I never really liked the wheels in white, mainly because i had to clean so often
So i had them powdercoated in dark grey.Also the front brakes were awfull, the discs were warped, the pistons were siezed to start with on one side, and it was just dangerous. So i Picked up a set of Fiat coupe turbo brembo calipers, New focus RS EBC plain discs and Mintex pads.
Made a set of brackets up using a piece of 5/8" thick alluminium, and bolted them all up, the brackets werent perfect and ended up with the caliper sat about 3mm too far out, although it worked perfectly so i left it.
Then the Girlfriend got us a Stunning new steering wheel for christmas to replace that awfull Momo one
At the same time i retrimmed my headlining and fitted my new leather interior, the original cloth seats were ok but the door cards were tatty.
I drove the car for a few months without really changing much, just sorting out little bits and bobs and getting bored with 300bhp
I had the car on a local hub dyno at a bit of a meet, it made 293bhp and about 320 ft/lb before the clutch let go
would have probably just pipped 300bhpSo i dropped the gearbox, had the flywheel skimmed and fitted an AP 6 paddle, at the same time i picked up another set of new wheels off Martin@Reyland and had them powder coated. When i came to fit them it turned out my previous slight cock up with the caliper brackets meant the wheels wouldnt fit
i ended up having to remake the brackets and run 6mm spacers on the front to clear them making the front ET29. I put a set of 5mm spacers on the rear too to bring them to ET30.
First show for the car then, Modified Live at oulton park with Cheshire RSOC, Girlfriends brother Chris (slammedorion) gave the car a quick Mop and polish the night before
The car was running well, but using a bit too much for my liking, Valve stem Oil seals/guides i believe. i thought about rebuilding the top end but it would still be on a 90kish 205 block and 2wd pistons
So the other weekend, i headed up to aberdeen with my brother, in my mums little clio as it does over 50mpg, and picked this up
One of Yum's old engines Spec is:
Small turbo Escort 200 block
ARP long stud and nut kit
WRC 4 layer SS head gasket
Touring Car spares Gated sump
7.6-1 Comp Ratio
ARP big end bolts
ported & flowed Cyl Head
MA spec inlet Cam
Kent Vernier pullys
Double Valve springs
Small turbo Inlet manifold plenum and throttle body
Rochester 1000cc injectors
Turbo Technics T38 turbo
Made 466bhp a few years ago
So this weekend, after a couple of weeks collecting up parts, I got the new engine in.
Started off looking like this:
3 hours later:
Then gave the engine bay a soaking with TFR and a scrub with a paintbrush
Whipped the sump off to drill and tap for my Oil temperature gauge
Touring cars gated sump, very nice
spent a few hours swapping stuff over last night, and then this morning a mate popped round and gave us a lift:
Still not liking the yellow inlet
I will get it up and running then spend a day sorting bits like that.Hopefully this week i can get it all connected up, and then get it mapped and back on the road
Last edited by fraser9764; 29-08-2015 at 08:26 PM.
22-05-2011, 11:35 PM
#6
Advanced PassionFord User
Very nice mate looking great.
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23-05-2011, 09:14 AM
#11
PassionFord Post Whore!!
Hope I'm not behind it when that rear diff explodes lol. Its certainly changed for the better over a year.
Keep up the good work.
Keep up the good work.
Last edited by slammedorion; 23-05-2011 at 09:16 AM.
23-05-2011, 07:42 PM
#13
cossie fan (unluckerly)
You must have a guardian angel lol i smashed my standard 7.5 inch diff to bits with 350 bhp and the same ish torque then fitted a gripper tunned the car to 500 bhp with the same ish torque and took all the teeth off the crown wheel and pinion! and no i dont drive like a twat 
also took the gear box out with 350 too!
also took the gear box out with 350 too!
23-05-2011, 07:44 PM
#14
Cheers for the replies 
put my new loom in tonight but not taken any pics as i left my phone in my overalls in work
Turbo Technics T38
Cheers i think i will have to pick up a good standard diff! Mine wont stand a chance
But mine is fooked now lol, whines like mad and clattering and banging
Meant to ask you actually, when you took us out in your saph did it have the 6 degree rear beem fitted? or was that for the escort?
put my new loom in tonight but not taken any pics as i left my phone in my overalls in work i think i will have to pick up a good standard diff! Mine wont stand a chance But mine is fooked now lol, whines like mad and clattering and banging
Meant to ask you actually, when you took us out in your saph did it have the 6 degree rear beem fitted? or was that for the escort?
28-05-2011, 09:25 AM
#15
Been busy this week, new engine is not too far off running now, still got to stick some jubilees on the breather system, connect amal valve and MAP sensor, sort some alternator belts as my new ones are too long, connect up the loom, rewire fans and pump and change the pump. should have it all done by monday
28-05-2011, 10:45 AM
#16
Cheers for the replies put my new loom in tonight but not taken any pics as i left my phone in my overalls in work
Turbo Technics T38
Cheers i think i will have to pick up a good standard diff! Mine wont stand a chance
But mine is fooked now lol, whines like mad and clattering and banging
Meant to ask you actually, when you took us out in your saph did it have the 6 degree rear beem fitted? or was that for the escort?
put my new loom in tonight but not taken any pics as i left my phone in my overalls in work Turbo Technics T38
Cheers
i think i will have to pick up a good standard diff! Mine wont stand a chance But mine is fooked now lol, whines like mad and clattering and banging
Meant to ask you actually, when you took us out in your saph did it have the 6 degree rear beem fitted? or was that for the escort?
28-05-2011, 05:44 PM
#18
Well it made 466bhp when it was in YUM, and its a very similar spec to cossie4i's car, ill be happy with anything over 450.
cheers matey
Got a bit more done today, new loom all plugged in now, had to extend and reroute both the CTS sensors and ACT sensor cabling to suit the small turbo head and manifold.
sorted the alty belts too, someone was being a bit dim last time they looked at it
fan rewire and put some fluids in tomorrow
29-05-2011, 08:52 PM
#23
Nice one
Cheers Glenn
Yep thats the one! Thanks.
had another few hours on it this afternoon after the F1, Engine bay is pretty much finished now, just got to put fluids in.
Just got to swap and rewire the pump tomorrow.
Moved my amal valve to the inner wing and extended the wiring, never liked it stuck to the slam panel with the wiring draped accross, much tidier
Yep thats the one! Thanks.
had another few hours on it this afternoon after the F1, Engine bay is pretty much finished now, just got to put fluids in.
Just got to swap and rewire the pump tomorrow.
Moved my amal valve to the inner wing and extended the wiring, never liked it stuck to the slam panel with the wiring draped accross, much tidier
03-06-2011, 08:02 PM
#24
Finally got her fired up this morning
Runs really nicely, very pleased, not even a noise from the lifters and the engines not been run since 2006 i think.
Tony@turbosystems sorted a base map out for us last night,
Started off by pulling the dizzy out and spinning the oil pump drive for a few minutes with a drill to get some oil round the engine, oil pressure looked good.
Popped a new dizzy and rotor arm on and the leads from my old engine as im waiting for new leads from R&B motorsport to suit the small turbo cam cover and dizzy, spun her over without the coil connected, then plugged her in and nothing
plenty of fuel, but no spark
after an hour of head scratching i realised some muppet had connected up the earth to the coil rewire loom not the live, swapped this round, and she fired straight up
i then spent the rest of the day trying to sort the banjo sealing washers on my 044 pump think ive got it sorted now.
Need a to sort a PF09 throttle position sensor, get that fitted and get it booked in for live mapping oh and re-do my half moon seals on the cam cover as its leaking already
Runs really nicely, very pleased, not even a noise from the lifters and the engines not been run since 2006 i think.
Tony@turbosystems sorted a base map out for us last night,
Started off by pulling the dizzy out and spinning the oil pump drive for a few minutes with a drill to get some oil round the engine, oil pressure looked good.
Popped a new dizzy and rotor arm on and the leads from my old engine as im waiting for new leads from R&B motorsport to suit the small turbo cam cover and dizzy, spun her over without the coil connected, then plugged her in and nothing
plenty of fuel, but no spark
after an hour of head scratching i realised some muppet
had connected up the earth to the coil rewire loom not the live, swapped this round, and she fired straight up i then spent the rest of the day trying to sort the banjo sealing washers on my 044 pump
think ive got it sorted now.Need a to sort a PF09 throttle position sensor, get that fitted and get it booked in for live mapping
oh and re-do my half moon seals on the cam cover as its leaking already
Last edited by fraser9764; 03-06-2011 at 08:04 PM.
03-06-2011, 09:58 PM
#27
Yep Gonna just take it back to ally i think, or nice boring black.
I Might do it tomorrow actually, dont know what to do with myself now, been flat out on this for two weeks and all i can do now is get a jubilee clip and tidy up the battery cables
Gonna just take it back to ally i think, or nice boring black.I Might do it tomorrow actually, dont know what to do with myself now, been flat out on this for two weeks and all i can do now is get a jubilee clip and tidy up the battery cables
03-06-2011, 10:01 PM
#28
i had wired it up about 3 weeks ago on the old loom and it was perfect, and yet i still managed to cock it up The amal valve is far better over on the inner wing, well worth the effort of pulling the wiring back through the loom and extending it a bit. looked lost stuck in the middle of nowhere before.
06-06-2011, 09:23 PM
#32
nope, spent the day fiddling with my mums citroen 2cv instead will do it soon.
Trying to resist the urge to order a carbon heat sheild, plug lead cover and cambelt cover at the mo someone sell me a standard cambelt cover quick
New TPS will hopefully be here tomorrow or wednesday, then ill see if Tony can do owt before the weekend, want to get out and use it
Steve, have you got a copy of you graph to hand? interested to see how it compares to the old graph for my engine?
will do it soon.Trying to resist the urge to order a carbon heat sheild, plug lead cover and cambelt cover at the mo
someone sell me a standard cambelt cover quick New TPS will hopefully be here tomorrow or wednesday, then ill see if Tony can do owt before the weekend, want to get out and use it
Steve, have you got a copy of you graph to hand? interested to see how it compares to the old graph for my engine?
06-06-2011, 09:45 PM
#35
hmmm interesting, yours seems to be about 250 rpm earlier coming on song, and starts to tail off at the top, where mine is still rising/leveling out.
i expected it to be the other way round as it was run on a 4wd exhaust manifold in YUM looking at old pictures, from what ive read the 4wd manifold should help spool up but restrict top end power
i expected it to be the other way round as it was run on a 4wd exhaust manifold in YUM looking at old pictures, from what ive read the 4wd manifold should help spool up but restrict top end power
07-06-2011, 06:36 PM
#40
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Nice car, but the front bumper looks like it needs sorting(gap between front wing and bump). And why the change of head? thought the older type were better than the new ones?
good luck!
good luck!
