545 bhp Radiant Red Sapphire Cosworth
26-06-2016, 11:06 PM
#802
The blanking panel is to mount a display which will be connected to the ECU.
Not sure yet exactly how I am going to do it, but thought I'd make a start anyway. There are a few options and I'm still weighing up what is best.
3dr hubs have a lower TCA and steering arm pick up point, which corrects the roll centre and bump steer when lowered.
Not sure yet exactly how I am going to do it, but thought I'd make a start anyway. There are a few options and I'm still weighing up what is best.
3dr hubs have a lower TCA and steering arm pick up point, which corrects the roll centre and bump steer when lowered.
26-06-2016, 11:56 PM
#803
PassionFord Post Troll
Love this car, didn't know that's what the difference is with the 3dr hubs.
Didn't realise the front bearings are taper bearings so makes it easy for diy change without a press. Just need to press the races in and the rest just sits in easily does it?
My hubs look tatty they're the only un powdercoated part on the front end left to do so I might strip them and get them coated.
Didn't realise the front bearings are taper bearings so makes it easy for diy change without a press. Just need to press the races in and the rest just sits in easily does it?
My hubs look tatty they're the only un powdercoated part on the front end left to do so I might strip them and get them coated.
27-06-2016, 09:27 AM
#804
Cheers, Yes the front bearings are easy to do. Worst bit is undoing the nut. They are something like 350nm. Easiest way I find is to put the hubs in the vice clamped on the studs and then use a long 1/2" breaker bar, with a 4ft extension, and then pull like hell 
Struggle to get them done up to torque as well even with a big 3/4 torque wrench.
Difference between saph and 3dr hubs
Struggle to get them done up to torque as well even with a big 3/4 torque wrench.
Difference between saph and 3dr hubs
27-06-2016, 11:04 AM
#805
I think you will like the feeling with the 3dr hubs. I fitted them to my 24v Sapph a few years ago, coming from standard Sierra hubs (which are much like Sapph cos hubs geometry wise). I thought it was an enormous improvement, turn in felt a lot more direct and there was also more feeling in the steering. I never expected such a big difference from such a 'simple' geometry change.
27-06-2016, 01:32 PM
#806
PassionFord Post Troll
I think you will like the feeling with the 3dr hubs. I fitted them to my 24v Sapph a few years ago, coming from standard Sierra hubs (which are much like Sapph cos hubs geometry wise). I thought it was an enormous improvement, turn in felt a lot more direct and there was also more feeling in the steering. I never expected such a big difference from such a 'simple' geometry change.
27-06-2016, 01:34 PM
#807
PassionFord Post Troll
Cheers, Yes the front bearings are easy to do. Worst bit is undoing the nut. They are something like 350nm. Easiest way I find is to put the hubs in the vice clamped on the studs and then use a long 1/2" breaker bar, with a 4ft extension, and then pull like hell
Struggle to get them done up to torque as well even with a big 3/4 torque wrench.
Difference between saph and 3dr hubs
Struggle to get them done up to torque as well even with a big 3/4 torque wrench.
Difference between saph and 3dr hubs
That's crazy tight on the front hubs lol
30-06-2016, 07:11 PM
#809
Made a start swapping the exhaust manifold yesterday. It's still running a 4x4 manifold at the moment, which is apparently restrictive overy 450bhp
Stripped down
4x4 manifold was looking a bit worse for wear. No evidence of it actually blowing though.
The new manifold
And some of the most expensive bolts in history
Turbo bolted up to the new manifold
Old exhaust off. Good riddance every time I have to touch that thing it ends up getting thrown down the garden
New setup mocked up to rotate the core and compressor housing to suit the new manifold.
Had to make a new actuator mount. Coat of primer on it here, it's since had a coat of satin black
Just got to bolt it all back on the car over the next few days. A few other bits to sort then it can go for a new exhaust and another run on the dyno to adjust the map.
Stripped down
4x4 manifold was looking a bit worse for wear. No evidence of it actually blowing though.
The new manifold
And some of the most expensive bolts in history
Turbo bolted up to the new manifold
Old exhaust off. Good riddance
every time I have to touch that thing it ends up getting thrown down the garden
New setup mocked up to rotate the core and compressor housing to suit the new manifold.
Had to make a new actuator mount. Coat of primer on it here, it's since had a coat of satin black
Just got to bolt it all back on the car over the next few days. A few other bits to sort then it can go for a new exhaust and another run on the dyno to adjust the map.
30-06-2016, 07:39 PM
#811
PassionFord Post Troll
Read your build thread from start to finish the other night you've done a great job, same story line as mines aswell lol.
Gimme some infos on those bolts I love 12 sided bolts they give stuff a kind of aircraft finish and yours look titanium aswell lol.
Gimme some infos on those bolts I love 12 sided bolts they give stuff a kind of aircraft finish and yours look titanium aswell lol.
01-07-2016, 11:19 PM
#815
Manifold bolted back on tonight
Checked that the heat shield is still going to fit.
Had to trim a few bits, luckily it's not mint so I'm not fussed on cutying it about.
Sits a fair bit higher than it did but still looks ok. Might make an aluminium shield for the bits that aren't covered.
And yes the bonnet still shuts.
Still got a few bits to sort this weekend but we're getting there
Checked that the heat shield is still going to fit.
Had to trim a few bits, luckily it's not mint so I'm not fussed on cutying it about.
Sits a fair bit higher than it did but still looks ok. Might make an aluminium shield for the bits that aren't covered.
And yes the bonnet still shuts.
Still got a few bits to sort this weekend but we're getting there
07-07-2016, 06:06 AM
#817
I know its ridiculous. The heat shield was one of the few nice bits on the original car but its been trimmed in a fair few places already due to cracking and fitment. Still looks nice though.
Decided I didn't want a turbo hanger off the cam cover as it would spoil the look of the engine bay, and being a small turbo head it would need to be custom made. Plus it would be a pain in the ass to fit around the heat shield and would need removing to check/change the plugs.
Unfortunately the small turbo head has no lug to mount a 2wd or RS500 damper
Decided to make some brackets and a support from below, much in the same way the inlet bracket works.
Time will tell if it works I guess. should be fine though
Also changed the alternator tensioner at the same time
Brackets have now been temporarily made for the turbo heat shield.
I will finalise these once the exhaust is made/fitted.
Then made a start on fitting the new 17mm inlet plenum spacer
Nice and easy to fit. Just had to drill out the threads on the fuel rail mounts and use nyloc nuts on the inside as there was no way of getting a bolt in from the inside with this fuel rail. Can just about get a stubby 10mm spanner in there to hold the nut whilst you tighten the bolt.
Few bits to finish tonight. Main one will be modifying the inlet support mount as that's moved by 17mm. The rest of it should just bolt back together as before hopefully.
Decided I didn't want a turbo hanger off the cam cover as it would spoil the look of the engine bay, and being a small turbo head it would need to be custom made. Plus it would be a pain in the ass to fit around the heat shield and would need removing to check/change the plugs.
Unfortunately the small turbo head has no lug to mount a 2wd or RS500 damper
Decided to make some brackets and a support from below, much in the same way the inlet bracket works.
Time will tell if it works I guess. should be fine though
Also changed the alternator tensioner at the same time
Brackets have now been temporarily made for the turbo heat shield.
I will finalise these once the exhaust is made/fitted.
Then made a start on fitting the new 17mm inlet plenum spacer
Nice and easy to fit. Just had to drill out the threads on the fuel rail mounts and use nyloc nuts on the inside as there was no way of getting a bolt in from the inside with this fuel rail. Can just about get a stubby 10mm spanner in there to hold the nut whilst you tighten the bolt.
Few bits to finish tonight. Main one will be modifying the inlet support mount as that's moved by 17mm. The rest of it should just bolt back together as before hopefully.
10-07-2016, 08:47 AM
#820
It will be interesting to see the difference when it's back on the dyno in a week or so. Unfortunatly I've changed a couple of things so it's difficult to say exactly the effect that changin the manifold has had.
Inlet manifold however; you are incorrect. The small turbo inlet plenum is the best designed of the original Ford manifolds. I may be wrong but Rod only swapped to a Hart inlet at 700ish.
No idea what you mean by 'chassi dyno!'....
Anyway i'll refer you back to an earlier post
End result, 545bhp and 490lb/ft 
I know this will probably divide opinion and some people will write it off as bullshit, and to be honest I don't care. Chris's dyno is proven thousands of times over to be accurate, and he's had much more powerful vehicles than my knackered old saph on there.
I know this will probably divide opinion and some people will write it off as bullshit, and to be honest I don't care. Chris's dyno is proven thousands of times over to be accurate, and he's had much more powerful vehicles than my knackered old saph on there.
Last edited by fraser9764; 10-07-2016 at 08:52 AM.
10-07-2016, 09:00 AM
#821
All back together except a couple of bits. Still missing the turbo oil drain pipe 
All needs a good clean again
Pinched the wifes car yesterday to take the cossie for its new exhaust
All needs a good clean again
Pinched the wifes car yesterday to take the cossie for its new exhaust
Last edited by fraser9764; 10-07-2016 at 09:04 AM.
10-07-2016, 09:06 AM
#822
PassionFord Post Whore!!
Exhaust manifold; I agree. I've never heard of another car making as much power on a 4x4 manifold. That's because the 4x4 manifold is widely regarded as insuperior to the 2wd, so everyone changes to 2wd as soon as they go looking for power. Who has avtually tried to run a 4x4 manifold at this power level before?
It will be interesting to see the difference when it's back on the dyno in a week or so. Unfortunatly I've changed a couple of things so it's difficult to say exactly the effect that changin the manifold has had.
Inlet manifold however; you are incorrect. The small turbo inlet plenum is the best designed of the original Ford manifolds. I may be wrong but Rod only swapped to a Hart inlet at 700ish.
No idea what you mean by 'chassi dyno!'....
Anyway i'll refer you back to an earlier post
It will be interesting to see the difference when it's back on the dyno in a week or so. Unfortunatly I've changed a couple of things so it's difficult to say exactly the effect that changin the manifold has had.
Inlet manifold however; you are incorrect. The small turbo inlet plenum is the best designed of the original Ford manifolds. I may be wrong but Rod only swapped to a Hart inlet at 700ish.
No idea what you mean by 'chassi dyno!'....
Anyway i'll refer you back to an earlier post
Mark
10-07-2016, 11:03 AM
#824
PassionFord Post Whore!!
The problem is working out what the looses on a dyno pack. I will be running rods on all the dynos avl to be able to correctly cross reference the power from the diff makes and readings the dynos give.
Mark
10-07-2016, 11:04 AM
#825
PassionFord Post Troll
What about if it had a plenum spacer would that make a difference?
10-07-2016, 11:18 AM
#826
PassionFord Post Whore!!
10-07-2016, 11:31 AM
#827
It may well be restricting, But as I'm not chasing every last HP i'm not too fussed. hopefully the spacer will help anyway.
The cost of the hart manifold compared to the increase in power for me just isn't worth it.
I'd rather put that money towards a change of turbo at some point in the future. And if I change turbo it wouldn't be to gain power it would still be aiming for 500ish but an increase in response/spool
So from that statement you are claiming EFI-Parts dyno to be incorrect, and also every other rolling road type chassis dyno...
For what it's worth EFI-Parts tunes some of the quickest drag cars in the country (specifically fwd stuff as this is Chris's main interest). The Dyno is a 1000bhp superflow which has been proven time and time again. For example we took our 206 GTI 180 Rally car in for mapping. A fairly healthy engine, Jenvey ITB's and DTA S60, and it made 170bhp... Hardly making ridiculous claims now is it?
10-07-2016, 11:35 AM
#829
PassionFord Post Troll
Tbh mate marks already confirmed that you can get as near as dammit your power figure from a st inlet so I wouldn't worry about it, it's a stunning car and I bet it goes like fuck so that's all that matters really.
10-07-2016, 11:36 AM
#830
It can flow that but it is starting to restrict it. The most I have seen on one was 523hp on a gt3076.
The problem is working out what the looses on a dyno pack. I will be running rods on all the dynos avl to be able to correctly cross reference the power from the diff makes and readings the dynos give.
Mark
The problem is working out what the looses on a dyno pack. I will be running rods on all the dynos avl to be able to correctly cross reference the power from the diff makes and readings the dynos give.
Mark
Whether the figure that it produces is 100% accurate is largely irrelevant.
The main thing is that it's repeatable.
And it is nice for the figure to be comparable against other dynos across the country, which based upon the other cars that have been on EFIs dyno I am happy enough that they are.
10-07-2016, 07:02 PM
#832
PassionFord Post Whore!!
This engine has always done 500 plus bhp every time on rolling roads
Every mod you've done it's just got bigger and bigger figures
I dread to think what it does on its next visit
Originally I'm sure it did 3 rolling road days and give low 500's every time
With the recent ecu change its give 540 odd
Looking at 1300gt's posting history, I'm sure it won't be long before he crawls back under the rock he come from...
Every mod you've done it's just got bigger and bigger figures
I dread to think what it does on its next visit
Originally I'm sure it did 3 rolling road days and give low 500's every time
With the recent ecu change its give 540 odd
Looking at 1300gt's posting history, I'm sure it won't be long before he crawls back under the rock he come from...
Last edited by slammedorion; 10-07-2016 at 07:06 PM.
16-07-2016, 06:58 PM
#834
New exhaust 
New from the turbo back. 3" that splits into 2x2.5" center boxes. It's a 3.5" tailpipe.
Custom Made by BCS Power valve in St Helens. Lovely job. Can't fault the quality and workmanship. It's the best fitting exhaust I've seen on a cossie. Fits perfectly around the diff and beam, and the twin centre box sits nicely up under the rear seat base. Must have an extra couple of inches groud clearance over most cossie exhausts.
Not been able to start it yet to see how it sounds as ive got a few bits left to do tomorrow.
New from the turbo back. 3" that splits into 2x2.5" center boxes. It's a 3.5" tailpipe.
Custom Made by BCS Power valve in St Helens. Lovely job. Can't fault the quality and workmanship. It's the best fitting exhaust I've seen on a cossie. Fits perfectly around the diff and beam, and the twin centre box sits nicely up under the rear seat base. Must have an extra couple of inches groud clearance over most cossie exhausts.
Not been able to start it yet to see how it sounds as ive got a few bits left to do tomorrow.
Last edited by fraser9764; 16-07-2016 at 07:04 PM.
16-07-2016, 07:50 PM
#837
Fart of the Purniture
The exhaust looks marvellous!
As does the underside of your car, I assume you did some kind of resto/treatment then painted it red, or was it already that good?
As does the underside of your car, I assume you did some kind of resto/treatment then painted it red, or was it already that good?
16-07-2016, 09:31 PM
#839
Cheers Glenn. Its not mint but it's not too bad. Makes it nice to work on. It's been out in all weathers including snow. Just gets a quick blast of snow foam every now and again.
Last edited by fraser9764; 16-07-2016 at 09:35 PM.