Gloss Black Escort Cosworth - Complete Resto

CossieGirl · 15-01-2012, 06:09 PM

After 1,5 year of fixing 1 thing only to find out something else broke aswell we decided to stop messing around and doing a complete resto.
We know what it means to own a Cosworth as this is our 6th one but this one is really testing our patience...
It turned out the car has more issues than we thought but as there's no point in thinking about decisions made in the past it's time to get our act together and get things sorted properly!

Just going to give a short summary of the work we did before deciding on a complete resto.

The day it arrived

30 mins later the stickers and sidelights were history

The clock was fixed as it had the traditional issues

Easy fix

Also had the all the clocks (speedo/rev/...) etc refurbished so no blotchy dials anymore

If you want yours done go to the ERSC and contact "cozzed"!!

Managed to source a brand new Magnex exhaust

First plan was to tidy everything up a bit and get it on the road asap.
Some bits removed

Sourced some new parts:
- New sensors (YB Air Temp Sensor, YB Coolant Temperature Sensor, 4x4 YB 82degree Thermostat, Cosworth Dashboard Temperature Gauge Sender Unit & Phase Sensor)
- New uprated fan switch, distributor cap & rotor arm
- New alternator
- Adjusted fuelrail with braided hoses
- New filters, coolant, oil, ...
- Tidied up some wiring as that was a right mess

Looking a lot better!

Soon after the waterpump decided to call it quits

Replaced that so it was finally running! Wheels were at the powdercoaters so put on MO's of a friend.
Suspensions still needed to be sorted...

With standard shocks, Ahmed springs and Brembo's fitted

At that time the steering rack started to leak

Luckily we found another one at the ERSC-forum

Had some parts resprayed and put our own wheels on again.

We took apart the complete interior, got about all the parts new that were damaged or scratched, removed the cloth / washed it / assembled the lot, put in some Defi's, installed an electric sunroof, ... = one very nice interior

Unfortunately it turned out the car was smoking blue heavily when backing off on the throttle.
First we thought it was the turbo so we had that rebuilt but no luck. Installed an oil separator and cleaned out the inlet side. Still no luck

So now we get to the point were we are now: in stead of just having the engine rebuilt we decided to go all the way and get everything sorted out. That means no trip to the UK in the EsCos this year either and 2013 won't be happening either I'm afraid but we WILL get there and when we do it will be in a very nice EsCos

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CossieGirl · 15-01-2012, 06:14 PM

Day 1

The one in charge of the workshop manual!

A few hours and a lot of scratched fingers later the head was off.

Last stuff removed before the block was lifted out.

CossieGirl · 15-01-2012, 06:16 PM

Ready to go...

Out at last.

Looking sorry for itself...

jonfoc · 15-01-2012, 06:17 PM

Lovely looking car, good luck with the resto. Keep the pics coming

CossieGirl · 15-01-2012, 06:20 PM

General underside picture. Not mint of course but I've seen worse...

He just thinks we're out of our minds... Can you blame him?

Everything stacked up in the basement. Wonder when it will be seeing some daylight again

More to follow in the next few years LOL

Fraggle... · 15-01-2012, 06:27 PM

Gorgeous in black.

On a stranger note..its propper cool to see parts removed and stored so careingly

Keep the updates coming, got a feeling this is going to be a good thread

CossieGirl · 16-01-2012, 07:35 AM

LOL
Well I'm "pretty well" (read: freakishly) organized by nature and those parts are too expensive to have them lying around (and getting lost) imo

MadMac · 16-01-2012, 07:41 AM

Nice looking cossie

Look forward to seeing how this progresses

garrett · 16-01-2012, 08:01 AM

really top job
like it with them comp though

Brian · 16-01-2012, 10:26 AM

Nice project

Brian

BigErn · 16-01-2012, 10:29 AM

Will be a minter when its done

CossieGirl · 16-01-2012, 10:53 AM

Thanks

@garrett: I'm one of the few people that doesn't like those comps (although they look better with Sierra offset) or the 18" monte wheels

DaxRiders · 16-01-2012, 11:01 AM

Where are you in belgium ? I'm near the border, near veurne.

Good luck for the resto

Fraggle... · 16-01-2012, 11:21 AM

Quote:

Originally Posted by CossieGirl

LOL
Well I'm "pretty well" (read: freakishly) organized by nature and those parts are too expensive to have them lying around (and getting lost) imo

Ditto, i even clean my broken parts up if i can once the jobs finished....just done my clutch and once i had finished i then cleaned old one up and put it in the box the new-un came in

But as my old boss used to say..,

"you can tell the quality of someone's work buy their house keeping..So get your S**T in order!!"

Suppose its just how i was taught, but its how i like to do things anyway

Anyway i wont clutter your thread anymore with OCD talk

Lovely motor op

CossieGirl · 16-01-2012, 06:26 PM

Quote:

Originally Posted by DaxRiders

Where are you in belgium ? I'm near the border, near veurne.

Good luck for the resto

I'm on the other side of the country near the border with The Netherlands

Quote:

Originally Posted by Fraggle...

Anyway i wont clutter your thread anymore with OCD talk

Lovely motor op

Thanks

Sticky. · 16-01-2012, 08:03 PM

Watching with interest. Looks superb on the wolf alloys with no spoiler.

TommyB · 16-01-2012, 08:32 PM

Great looking Escort, Those houses in belgium are awesome too,my friend keeps a mini cooper S and a fiat 500 abarth in his basement.

grcossie · 16-01-2012, 08:40 PM

Nice one this, i think you have to sell it to me

CossieGirl · 17-01-2012, 07:47 AM

Quote:

Originally Posted by Sticky.

Watching with interest. Looks superb on the wolf alloys with no spoiler.

Can't really decide on the big spoiler...
Just need to source another lower spoiler and then we have 2 tailgates we can change over.

Quote:

Originally Posted by TommyB

Great looking Escort, Those houses in belgium are awesome too,my friend keeps a mini cooper S and a fiat 500 abarth in his basement.

Well... actually there are 2 Escort Cossies in the basement. My friend broke his 2 years ago for a full rebuild and apart from the shell and the engine all his stuff is in there aswell LOL

Quote:

Originally Posted by grcossie

Nice one this, i think you have to sell it to me

Everything is for sale

Had it up for sale for about a year but not one serious reaction...

grcossie · 17-01-2012, 09:37 AM

Must be a gatebil trip for yours, this year, whit escos and Focus. Then you can just leave the escos to me.
How much did you advert it for?

CossieGirl · 01-05-2012, 12:40 PM

Not that much progress but we're also doing a lot of work on the house as well...
Aiming to get it ready in 2015!

Camcover, oilfilter arm and engine mounts painted.

The "fun" part.

High pressure oilpump from Mike R.

Some gaskets

CossieGirl · 01-05-2012, 12:40 PM

Some more paintwork.

Skirts removed resulting in 2 spots of rust.
Left

Same place right side.

Head ready for reassembly

The result.

CossieGirl · 01-05-2012, 12:41 PM

New original Borg & Beck clutch set.

New forged pistons 1st oversize from Mike R.

Camshaft pulleys cleaned

Alloy crankshaft pulley on its way from Stu

So the block is ready for a rebore.

CossieGirl · 01-05-2012, 12:41 PM

Continued to strip down the shell and got it up in a carspit at the front.

Want to get the underside done this summer. Tips to remove the underseal are always welcome

garrett · 01-05-2012, 06:30 PM

so very nice just lovely

fezzajsy · 01-05-2012, 08:08 PM

looking good

CossieGirl · 02-05-2012, 05:06 AM

Trial fitted the big spoiler just before winter and I think I'm going to put it back on...

PhilCook · 02-05-2012, 07:58 AM

Ooooooffff

That looks gorgeous!!

FordRSmania · 02-05-2012, 11:07 AM

really stunning when its be done! Loved to own a Cosworth but its gonna cost an awfull lot of money to rebuild it to this spec, credits to you. Keep up the good work
I think i will stick with my RS1600i and XR2

phil_rs · 02-05-2012, 11:59 AM

REALLY makes me miss my old gloss black one

Good luck with the build, looking good so far

turbo m · 02-05-2012, 08:55 PM

What a awsome looking cossie in black!!! i would personally keep the whale tail but thats just me it will be a stunner when finshed.Good luck and i will be watching this...

CossieGirl · 03-05-2012, 07:44 AM

Thanks

Hardest thing is not getting carried away as you want to do so many things at once...

S1 · 03-05-2012, 08:39 AM

That looks lovely! It's nice to see one that's kept the Hexagon trim, I much prefer it to the black leather.

0150carmac · 03-05-2012, 09:32 AM

like a good esc cossie and espically in black keep up the good work i will be watching

Robs Frst · 03-05-2012, 03:33 PM

Nice progress, looks great in that colour.

joffy · 03-05-2012, 03:43 PM

Really like that, although i must say i prefer it without the big wing

Twins · 03-05-2012, 03:46 PM

Superb

Glenn_ · 07-05-2012, 10:11 PM

That looks stunning.You have done a fair amount of work to it.

matman · 08-05-2012, 11:31 AM

Stunning car.

MARCOSWORTH · 16-05-2012, 05:30 AM

Nice resto Debbie

15-01-2012, 06:14 PM	#2
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Day 1 The one in charge of the workshop manual! A few hours and a lot of scratched fingers later the head was off. Last stuff removed before the block was lifted out. __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

15-01-2012, 06:16 PM	#3
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Ready to go... Out at last. Looking sorry for itself... __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

15-01-2012, 06:20 PM	#5
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	General underside picture. Not mint of course but I've seen worse... He just thinks we're out of our minds... Can you blame him? Everything stacked up in the basement. Wonder when it will be seeing some daylight again More to follow in the next few years LOL __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

15-01-2012, 06:27 PM	#6
Fraggle... Love's a bit of rock Garage is empty, add now Trader Score: (1) Join Date: Feb 2011 Location: There is a place not far from here... Posts: 1,016 Rep Power: 4	Gorgeous in black. On a stranger note..its propper cool to see parts removed and stored so careingly Keep the updates coming, got a feeling this is going to be a good thread __________________ Fiesta Turbo.Com,Love it For sale..XR/RS/CAB/FRST Parts. Once you've had Jap, you never go back...

16-01-2012, 07:35 AM	#7
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	LOL Well I'm "pretty well" (read: freakishly) organized by nature and those parts are too expensive to have them lying around (and getting lost) imo __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

15-01-2012, 06:17 PM	#4
jonfoc PassionFord Regular Garage is empty, add now Trader Score: (0) Join Date: May 2011 Location: Nottingham Posts: 496 Rep Power: 3	Lovely looking car, good luck with the resto. Keep the pics coming

16-01-2012, 07:41 AM	#8
MadMac 15K+ Super Poster!! Garage is empty, add now Trader Score: (0) Join Date: Apr 2004 Location: Croydon Posts: 16,548 Rep Power: 26	Nice looking cossie Look forward to seeing how this progresses

16-01-2012, 08:01 AM	#9
garrett Too many posts.. I need a life!! Garage is empty, add now Trader Score: (5) Join Date: Aug 2004 Posts: 617 Rep Power: 9	really top job like it with them comp though __________________

16-01-2012, 10:26 AM	#10
Brian 10K+ Poster!! Garage is empty, add now Trader Score: (2) Join Date: Aug 2003 Location: Essex Posts: 10,732 Rep Power: 20	Nice project Brian __________________

16-01-2012, 10:29 AM	#11
BigErn PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Nov 2006 Location: Sunderland Posts: 7,276 Rep Power: 14	Will be a minter when its done __________________ My Sapph work in progress http://passionford.com/forum/restora...ne-2011-a.html

16-01-2012, 10:53 AM	#12
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Thanks @garrett: I'm one of the few people that doesn't like those comps (although they look better with Sierra offset) or the 18" monte wheels __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

16-01-2012, 11:01 AM	#13
DaxRiders Virgin Garage is empty, add now Trader Score: (0) Join Date: Nov 2011 Location: France Posts: 14 Rep Power: 0	Where are you in belgium ? I'm near the border, near veurne. Good luck for the resto __________________ Ford Fiesta mk3 2.0 pinto RWD If it's not a rwd, it's not a car....

16-01-2012, 08:03 PM	#16
Sticky. 20K+ Super Poster. Garage is empty, add now Trader Score: (4) Join Date: Apr 2004 Location: Liverpool Posts: 23,083 Rep Power: 33	Watching with interest. Looks superb on the wolf alloys with no spoiler. __________________ www.mattlewismotorsportonline.co.uk www.richardburnsfoundation.com www.mt-motorsport.com

16-01-2012, 08:32 PM	#17
TommyB Boosted 122 cu in 1965 Ford Cortina Trader Score: (0) Join Date: Jul 2003 Location: Bedford Posts: 128 Rep Power: 10	Great looking Escort, Those houses in belgium are awesome too,my friend keeps a mini cooper S and a fiat 500 abarth in his basement.

16-01-2012, 08:40 PM	#18
grcossie Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: May 2007 Location: norway Posts: 965 Rep Power: 7	Nice one this, i think you have to sell it to me __________________ Sierra saphire 88 2wd Cosworth stg1 Escort Cosworth 93 stg3

17-01-2012, 09:37 AM	#20
grcossie Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: May 2007 Location: norway Posts: 965 Rep Power: 7	Must be a gatebil trip for yours, this year, whit escos and Focus. Then you can just leave the escos to me. How much did you advert it for? __________________ Sierra saphire 88 2wd Cosworth stg1 Escort Cosworth 93 stg3

01-05-2012, 12:40 PM	#21
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Not that much progress but we're also doing a lot of work on the house as well... Aiming to get it ready in 2015! Camcover, oilfilter arm and engine mounts painted. The "fun" part. High pressure oilpump from Mike R. Some gaskets __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350 Last edited by CossieGirl; 01-05-2012 at 12:43 PM.

01-05-2012, 12:40 PM	#22
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Some more paintwork. Skirts removed resulting in 2 spots of rust. Left Same place right side. Head ready for reassembly The result. __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

01-05-2012, 12:41 PM	#23
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	New original Borg & Beck clutch set. New forged pistons 1st oversize from Mike R. Camshaft pulleys cleaned Alloy crankshaft pulley on its way from Stu So the block is ready for a rebore. __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350 Last edited by CossieGirl; 01-05-2012 at 12:43 PM.

01-05-2012, 06:30 PM	#25
garrett Too many posts.. I need a life!! Garage is empty, add now Trader Score: (5) Join Date: Aug 2004 Posts: 617 Rep Power: 9	so very nice just lovely __________________

01-05-2012, 08:08 PM	#26
fezzajsy 10K+ Poster!! Garage is empty, add now Trader Score: (9) Join Date: Nov 2004 Location: jeRSey..isles Posts: 13,114 Rep Power: 22	looking good __________________ http://passionford.com/forum/restora...y-tidy-up.html

02-05-2012, 05:06 AM	#27
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Trial fitted the big spoiler just before winter and I think I'm going to put it back on... __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

02-05-2012, 07:58 AM	#28
PhilCook Too many posts.. I need a life!! Garage is empty, add now Trader Score: (1) Join Date: Oct 2009 Location: Manchester Posts: 550 Rep Power: 4	Ooooooffff That looks gorgeous!!

02-05-2012, 11:07 AM	#29
FordRSmania FordRSmania Garage is empty, add now Trader Score: (0) Join Date: Feb 2009 Location: Netherlands, 't Harde Posts: 214 Rep Power: 5	really stunning when its be done! Loved to own a Cosworth but its gonna cost an awfull lot of money to rebuild it to this spec, credits to you. Keep up the good work I think i will stick with my RS1600i and XR2 __________________ Fiesta XR2 mk2 resto: http://passionford.com/forum/restora...-xr2-85-a.html Escort RS1600i resto: http://passionford.com/forum/restora...m-holland.html

02-05-2012, 11:59 AM	#30
phil_rs yam yammer Garage is empty, add now Trader Score: (3) Join Date: Jan 2006 Location: Stourbridge, West Mids Posts: 2,645 Rep Power: 10	REALLY makes me miss my old gloss black one Good luck with the build, looking good so far __________________ Escort RS Turbo S2 Escort Bonus 1.9 turbo track car (Project "Grand Theft Auto") http://passionford.com/forum/restora...ort-bonus.html VW Passat 1.9 TDi 130 estate Black Country RS Owners Club & Performance Car Club.... all welcome! http://s15.zetaboards.com/Black_Country_RSOC/index/ http://www.mattlewismotorsportonline.co.uk/ http://www.carpartsexpress.co.uk/

02-05-2012, 08:55 PM	#31
turbo m PassionFord Regular Garage is empty, add now Trader Score: (2) Join Date: Jun 2010 Location: cambridge Posts: 459 Rep Power: 3	What a awsome looking cossie in black!!! i would personally keep the whale tail but thats just me it will be a stunner when finshed.Good luck and i will be watching this...

03-05-2012, 07:44 AM	#32
CossieGirl Miss Doubtsalot Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Belgium Posts: 1,028 Rep Power: 11	Thanks Hardest thing is not getting carried away as you want to do so many things at once... __________________ 1993 Gloss Black Ford Escort RS Cosworth 2003 Imperial Blue Ford Focus RS Mk 1 2009 Frozen White Ford Focus RS Mk 2 MP350

03-05-2012, 08:39 AM	#33
S1 ............... Garage is empty, add now Trader Score: (0) Join Date: Jul 2003 Location: Essex Posts: 2,665 Rep Power: 12	That looks lovely! It's nice to see one that's kept the Hexagon trim, I much prefer it to the black leather. __________________

03-05-2012, 09:32 AM	#34
0150carmac Regular Contributor Garage is empty, add now Trader Score: (0) Join Date: Mar 2012 Location: Bo'ness In The Garage Carmac Autos Posts: 300 Rep Power: 2	like a good esc cossie and espically in black keep up the good work i will be watching

03-05-2012, 03:33 PM	#35
Robs Frst PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: May 2006 Location: Watford/London Posts: 3,536 Rep Power: 11	Nice progress, looks great in that colour. __________________ Evo 6 - 410 Bhp soon to be 500bhp+ VW MK4 Golf GTI Turbo MK5 Golf GTI

03-05-2012, 03:43 PM	#36
joffy SLOW LEARNER Garage is empty, add now Trader Score: (1) Join Date: May 2006 Posts: 1,664 Rep Power: 9	Really like that, although i must say i prefer it without the big wing

03-05-2012, 03:46 PM	#37
Twins 15K+ Super Poster!! Garage is empty, add now Trader Score: (17) Join Date: Sep 2004 Location: ESSEX Posts: 16,763 Rep Power: 25	Superb __________________ My carbon clad s2

07-05-2012, 10:11 PM	#38
Glenn_ Chasing Radders Garage is empty, add now Trader Score: (1) Join Date: Jul 2006 Location: Darlington county durham Posts: 38,136 Rep Power: 45	That looks stunning.You have done a fair amount of work to it. __________________

08-05-2012, 11:31 AM	#39
matman Regular Contributor Garage is empty, add now Trader Score: (0) Join Date: Jul 2004 Location: In the garage..... Posts: 311 Rep Power: 9	Stunning car.

16-05-2012, 05:30 AM	#40
MARCOSWORTH PassionFord Post Whore!! Garage is empty, add now Trader Score: (21) Join Date: Dec 2004 Location: Nederland Posts: 3,928 Rep Power: 12	Nice resto Debbie __________________ Marco My Flint Grey Saph project