Mercury Grey Saff Cossie Replica - New cossie engine going in!
03-06-2011, 01:24 PM
#1
Mercury Grey Saff Cossie Replica - New cossie engine going in!
Think i might as well create a resto thread for this car as i reckon i will be working on this a fair bit until im happy with it. Good thing about having two Sierras is you can swap parts over 
To give you a background to the car. My Dad bought this car (Sierra Sapphire Ghia) brand new in March 1991, I was 15 at the time and tried my hardest to get him to change the Ghia to a Cossie but he wasnt having none of it - especially when he found how much it would be to insure the thing
We had the car for approx 16 years. I had to go on as a 2nd owner when i started to use it as a daily approx 10 years ago due to insurance purposes. I sold it about 6-7 years ago now. I will try and dig some early pics of the car as i had started to Cossie it back then, with side skirts and a Sierra 2000E steering wheel which is similar to the 2wd cossie wheels but with a grey edge.
Fast forward a few years ago and the car was in a yard near my mates workshop. Turns out some guy saw the car in a police impound yard and bought the car for a £100
He was getting the fabricators at the yard to cut the old rot out and replace with new. The donor car that was supplying the bits was on my mates ramp and i just happended to be there when this was getting cut out. From memory its had two complete new sills and the drivers rear arch sorted.
The new owner was going to do it as cossie rep and use it for drifting. He had also fitted a cossie cloth recaro interior at this point. When I bought the car this had been replaced with very good leather.
Then last year, this car turned up to our Middlesex meet when it was in the pub in Ashford and the new owner works fairly local to me so kept in touch.
This year, the owner was thinking of selling it, so i snapped it up for a fair bit of money considering its not a real Cosworth. However, the shell is very very clean, with excellent leather and retrimmed roof lining, doorcards and pillars.
I added the RS7s as i think they are a sexy looking wheel on the saff. This was actually my first mod since buying it. Forgive the crap pics - i will get better ones ive had a chance to polish it properly.
My second mod was to replace the 4x4 7" Cossie diff as it was whining more than Mall Cop Warren after seeing a motorbike overtake him 
Leaking diff...
And the replacement diff - courtesy from Gary @ RS Classics
Whilst the car was on the ramp, i thought i better take some pics to see how the underside is doing...
Looks like a leaky fuel tank in the above pic - so im only putting in £20 a time. However I have a spare tank in my garage which will go on later in the build.
One really annoying thing I hate about the car is noise from the exhaust
my cossie was quieter than this Not to mention its bloody embarrassing when you put your foot down, make a shit load of noise and not go anywhere
Can someone identify this exhaust please? The backbox has had a Scorpion 4" tailpipe welded on, but the only pic i have at the moment is below...
Quick check on the rest of the car underneath...
Its clean down there with all straight edges - considering getting it waxoiled to protect it a bit more.
As the previous owner had robbed the 200E steering wheel i put on, I decided I may pull the very good wheel out the 3dr along with its rare RS Centre horn push, so it looks more like a proper cossie.
My next mod was to do something about the shitty rear speakers Ford decided to supply. So after a quick check in my speaker drawer I found a pair of Sony speakers - however the metal screw holes were preventing fitment so a little modding had to be done. The finished result is this...
Now I just got to do the wiring for the amp/s and put my sub in the boot.
One quick pic from last night...
Might try my touring car mirrors that i got from Fudgey - they were destined for the 3dr but i think like most parts i have - they will probably find their way into the saff and then onto the 3dr.
Got my hocks to try on the Saff too
Next mod on the list is to replace the leaking rear coilovers with decent Koni dampers - im picking a set up tonight from Wembley and also picking a complete set up from Gary @ RS Classics along with a few other bits tomorrow. Want to get the shocks changed over tonight so i can drive the car properly.
Anyway, hope you like the thread - will be more of a modification thread than a resto thread as that work had already been done prior to me buying it
To give you a background to the car. My Dad bought this car (Sierra Sapphire Ghia) brand new in March 1991, I was 15 at the time and tried my hardest to get him to change the Ghia to a Cossie but he wasnt having none of it - especially when he found how much it would be to insure the thing
We had the car for approx 16 years. I had to go on as a 2nd owner when i started to use it as a daily approx 10 years ago due to insurance purposes. I sold it about 6-7 years ago now. I will try and dig some early pics of the car as i had started to Cossie it back then, with side skirts and a Sierra 2000E steering wheel which is similar to the 2wd cossie wheels but with a grey edge.
Fast forward a few years ago and the car was in a yard near my mates workshop. Turns out some guy saw the car in a police impound yard and bought the car for a £100
He was getting the fabricators at the yard to cut the old rot out and replace with new. The donor car that was supplying the bits was on my mates ramp and i just happended to be there when this was getting cut out. From memory its had two complete new sills and the drivers rear arch sorted.
The new owner was going to do it as cossie rep and use it for drifting. He had also fitted a cossie cloth recaro interior at this point. When I bought the car this had been replaced with very good leather.
Then last year, this car turned up to our Middlesex meet when it was in the pub in Ashford and the new owner works fairly local to me so kept in touch.
This year, the owner was thinking of selling it, so i snapped it up for a fair bit of money considering its not a real Cosworth. However, the shell is very very clean, with excellent leather and retrimmed roof lining, doorcards and pillars.
I added the RS7s as i think they are a sexy looking wheel on the saff. This was actually my first mod since buying it. Forgive the crap pics - i will get better ones ive had a chance to polish it properly.
My second mod was to replace the 4x4 7" Cossie diff as it was whining more than Mall Cop Warren after seeing a motorbike overtake him
Leaking diff...
And the replacement diff - courtesy from Gary @ RS Classics
Whilst the car was on the ramp, i thought i better take some pics to see how the underside is doing...
Looks like a leaky fuel tank in the above pic - so im only putting in £20 a time. However I have a spare tank in my garage which will go on later in the build.
One really annoying thing I hate about the car is noise from the exhaust
my cossie was quieter than this Not to mention its bloody embarrassing when you put your foot down, make a shit load of noise and not go anywhere Can someone identify this exhaust please? The backbox has had a Scorpion 4" tailpipe welded on, but the only pic i have at the moment is below...
Quick check on the rest of the car underneath...
Its clean down there with all straight edges - considering getting it waxoiled to protect it a bit more.
As the previous owner had robbed the 200E steering wheel i put on, I decided I may pull the very good wheel out the 3dr along with its rare RS Centre horn push, so it looks more like a proper cossie.
My next mod was to do something about the shitty rear speakers Ford decided to supply. So after a quick check in my speaker drawer I found a pair of Sony speakers - however the metal screw holes were preventing fitment so a little modding had to be done. The finished result is this...
Now I just got to do the wiring for the amp/s and put my sub in the boot.
One quick pic from last night...
Might try my touring car mirrors that i got from Fudgey - they were destined for the 3dr but i think like most parts i have - they will probably find their way into the saff and then onto the 3dr.
Got my hocks to try on the Saff too
Next mod on the list is to replace the leaking rear coilovers with decent Koni dampers - im picking a set up tonight from Wembley and also picking a complete set up from Gary @ RS Classics along with a few other bits tomorrow. Want to get the shocks changed over tonight so i can drive the car properly.
Anyway, hope you like the thread - will be more of a modification thread than a resto thread as that work had already been done prior to me buying it
Last edited by R4N SS; 10-09-2018 at 04:22 PM.
03-06-2011, 01:33 PM
#3
yep - its the only car my old man has ever bought brand new.
Ive even caught him staring at it in the drive from the upstairs window think he wishes he never sold it. i want to get it all sorted and driving nice with an exhaust you can actually live with, then I will throw him the car keys and tell him to put some juice in it
Ive even caught him staring at it in the drive from the upstairs window
think he wishes he never sold it. i want to get it all sorted and driving nice with an exhaust you can actually live with, then I will throw him the car keys and tell him to put some juice in it
Last edited by R4N SS; 03-06-2011 at 02:55 PM.
03-06-2011, 05:29 PM
#6
Regular Contributor
I agree, got a twinky pipe here and it matches. Look at the welds by the rear mount (or middle depending which way you look at it). Twinkys aint the quietest of engines when you effectivly have 2 resonator boxes and 1 muffler. Car looks really good, the cossy reps been done better than most I seen. Don't bother sticking the cossy motor in it, keep it for the 3 door (far less of those around). The twinky can be given a few mods to give it a good kick up the arse and still keep it a nice every day engine
04-06-2011, 10:05 AM
#7
Anyone got a centre box I can use - as its driving me mad and embarrassing when people expect you to put ur foot down, but u can't as it sounds so wrong
I'm convincing myself everyday not to put the Cossie engine in this. Did about 70 miles in it last night and quite like not having to stop at every petrol station. It goes well enough for a daily.
Got the rear coilovers off last night and they were both fucked car is sitting on konis now but is a little higher will get some pics later but it drives sooo much smoother - like a different car now
I'm convincing myself everyday not to put the Cossie engine in this. Did about 70 miles in it last night and quite like not having to stop at every petrol station. It goes well enough for a daily.
Got the rear coilovers off last night and they were both fucked
car is sitting on konis now but is a little higher will get some pics later but it drives sooo much smoother - like a different car now
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05-06-2011, 10:36 AM
#13
Thanks for the compliments guys.
Have decided to keep the engine as is until it expires as it's a great runner and is not too bad at motorway cruising speeds, if a little loud. Going to try and get hold of a middle box for this.
My job for today is to get a stereo wired in and some polish on. Gotta do the gardening first fucking better not rain this time 
Have decided to keep the engine as is until it expires
as it's a great runner and is not too bad at motorway cruising speeds, if a little loud. Going to try and get hold of a middle box for this. My job for today is to get a stereo wired in and some polish on. Gotta do the gardening first
fucking better not rain this time
13-06-2011, 03:32 PM
#16
I'm Finding My Feet Here Now
nice mate! i tried to buy my dads old ex essex police mk2 cortina gt 4dr last year, well the rolling shell i even offered the guy twice the price and told him id get it within the hour but he'd allready sold it on ebay :-(
13-06-2011, 09:09 PM
#19
Regular Contributor
The good thing about a twinky is if the head gasket is ok and the fan switch is working, you can kick it's head in all day and it'll be fine, I know, I've tried 
15-06-2011, 08:55 AM
#20
i need to check the fan switch. The temp gauge dont work but it was like that when i owned it years and years ago lol.
Need to drop the tank and check the fuel sender as thats reading wrong and the overflow leaks fuel everywhere underneath
Once its checked im going to get the crappy 15's on the back and smoke the local trading estate roundabout in the evening
Got a front strut brace to put on and a set of RS mudflaps but dont want to drill any holes in the metal
Need to drop the tank and check the fuel sender as thats reading wrong and the overflow leaks fuel everywhere underneath
Once its checked im going to get the crappy 15's on the back and smoke the local trading estate roundabout in the evening
Got a front strut brace to put on and a set of RS mudflaps but dont want to drill any holes in the metal
01-07-2011, 11:08 AM
#22
waiting on a 4 spoke sterring wheel to arrive and i can then put my mint 3dr cossie wheel (with rare rs horn push) away as good condition std wheels are getting very hard to come by - luckily it was on my white 3dr replica when i bought it so nice touch there.
Managed to get hold of a 4x4 plastic gear surround as mine is broken but its grey so will be painting that satin black.
Managed to get hold of a 4x4 plastic gear surround as mine is broken but its grey so will be painting that satin black.
06-07-2011, 03:15 PM
#23
Cossie engine is going into this car now as the 3dr project is on hold until more time and funds allow.
Trying to have it done for Ford Fair but time and money is not on my side 
GT30 has been ordered. I have most of the parts required but need to the following:
rebuild my T5 gearbox
possibly source and install ABS system
ECU + Chip (unless I buy my mates L6)
Injectors
2wd Inlet spacer
2wd Inlet throttle mod (not going Hart for now due to budget)
Hocks refurbed
Flamer kit
Im sure i have forgotten some other items lol
Only thing is my brakes wont clear the RS7s which im a bit gutted about
Trying to have it done for Ford Fair but time and money is not on my side
GT30 has been ordered. I have most of the parts required but need to the following:
rebuild my T5 gearbox
possibly source and install ABS system
ECU + Chip (unless I buy my mates L6)
Injectors
2wd Inlet spacer
2wd Inlet throttle mod (not going Hart for now due to budget)
Hocks refurbed
Flamer kit
Im sure i have forgotten some other items lol
Only thing is my brakes wont clear the RS7s which im a bit gutted about
06-07-2011, 07:42 PM
#24
Too many posts.. I need a life!!
Good idea sticking the cossie lump in this, its a clean and tidy shell and the YB will finish it off.
If you need a hand with the conversion gimme a shout mate ive pulled so many sierra engines out over the years lol.
Jim
If you need a hand with the conversion gimme a shout mate ive pulled so many sierra engines out over the years lol.
Jim
13-07-2011, 09:11 AM
#29
It will have a YB engine in there soon, as had a few nice presents waiting for me when i got home...
GT3076r with airfilter and hose
14mm inlet plenum spacer.
Im hoping to drop my T5 off to CTS this weekend, then all i need is a set of injectors.
Going to use the L6 my mate has as need to keep the costs down for now.
Should be good for 450-500bhp.
The exhaust that is on the car is WELL LOUD!
GT3076r with airfilter and hose
14mm inlet plenum spacer.
Im hoping to drop my T5 off to CTS this weekend, then all i need is a set of injectors.
Going to use the L6 my mate has as need to keep the costs down for now.
Should be good for 450-500bhp.
The exhaust that is on the car is WELL LOUD!
21-07-2011, 03:19 PM
#32
The current exhaust is fine if you are pootling around town but as soon as you put your foot down or are on the motorway - its far too much.
Got a set of front amber inidicators to go on - unfortunately they are non-genuine but brand new and i cant complain for what i paid for them.
Also, going to pick up an L8 ECU this evening from Paul Ripley.
CTS have confirmed it was just the synchros that were fucked in my box so hopefully it wouldnt cost the earth
now all i need is a clutch
Got a set of front amber inidicators to go on - unfortunately they are non-genuine but brand new and i cant complain for what i paid for them.
Also, going to pick up an L8 ECU this evening from Paul Ripley.
CTS have confirmed it was just the synchros that were fucked in my box so hopefully it wouldnt cost the earth
now all i need is a clutch
21-07-2011, 09:05 PM
#33
Quick update, bought some cheap Amber indicators from eBay so thought I'd try them on, although I'm not a 100% happy with the fitting yet so will mod them to sit a bit better
Sorry about the crap pics as it was getting dark
Also, just picked up an L8 ECU and wiring loom from Paul Ripley so that's another item off the list
Sorry about the crap pics as it was getting dark
Also, just picked up an L8 ECU and wiring loom from Paul Ripley so that's another item off the list
Last edited by R4N SS; 21-07-2011 at 09:08 PM.
