J18 COS Cosworth rebuild and restoration
13-10-2012, 07:31 PM
#1
J18 COS Cosworth rebuild and restoration
Thought I would share this with the fellow members as progress has really slowed down and the money pot is drying up with the run up to Christmas so i'll need some encouragement over the next few of month 
Started middle of June 2010 on weekends only
This is the first time I've done something as deep as this.
Before,
20 Years of crap underneath...
Started middle of June 2010 on weekends only
This is the first time I've done something as deep as this.
Before,
20 Years of crap underneath...
Last edited by Cossy Mike; 15-05-2020 at 09:14 PM.
13-10-2012, 07:32 PM
#3
Nightmare
one bolt siezed in, it took a couple of hours to get it out as needed to cut through it on both sides.....Also need to mount a work bench in the garage with a new vice as I'm not allowed to use works garage facilities any more due to someone stealing Diesel, so it's all stopped
13-10-2012, 07:33 PM
#4
Picked up some of my bits today and dropped some more off, all looking mint considering the state of the stuff I gave him.
Only problem is he's lost one of my rear beam plates, he promises me he has it somewhere
^^^^^^^^^^ so I thought.......it all needs re-done, not happy with it. As the saying goes, pay cheap, pay twice!
Never again!
Last edited by Cossy Mike; 14-10-2012 at 01:07 PM.
13-10-2012, 07:34 PM
#5
I'm hoping these come apart as easy as the rear driveshafts did.....
Not sure what happened here but I ordered new clips for the gearbox/exhaust heat shield (24mm) and these turned up
Not happy....All sorted thanks to Carparts Express in South Shields!!! 
13-10-2012, 07:35 PM
#6
Done my back in with this
Nearly lost my fingers as well,
I was not expecting it to be side heavy!Bad news is it looks like it needs an input shaft bearing done and a couple of seals
Last edited by Cossy Mike; 14-10-2012 at 01:07 PM.
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13-10-2012, 07:38 PM
#9
before and after
Had the diff blasted only and got it back like this. Really don't want to put any paint on it as it will likely peel or I'll get the wrong colour Silver and don't want it to look wrong.
Needs airing off and wiping down....
Had the diff blasted only and got it back like this. Really don't want to put any paint on it as it will likely peel or I'll get the wrong colour Silver and don't want it to look wrong.
Needs airing off and wiping down....
13-10-2012, 07:39 PM
#11
Been racing this weekend so not had much time to get much done
Is this the 'timing right' mark??
Head gasket was ok
However there are valve marks on the pistons : so not sure on the story there
What have I started!!!!! I think I've dug a too deeper hole
Is this the 'timing right' mark??
Head gasket was ok
However there are valve marks on the pistons :
so not sure on the story thereWhat have I started!!!!! I think I've dug a too deeper hole
13-10-2012, 07:44 PM
#18
It's out!
Not much progress being done at the moment and I lost a day today changing coolant, thermostat and fan switch on a friends Cossie. Moving radiator to the correct holes, trying to fix the gearstick and trying new clocks in for the temp gauge.
Waxoyl needs to be stripped and I got sick the other day starting it with petrol.
Not much progress being done at the moment and I lost a day today changing coolant, thermostat and fan switch on a friends Cossie. Moving radiator to the correct holes, trying to fix the gearstick and trying new clocks in for the temp gauge.
Waxoyl needs to be stripped and I got sick the other day starting it with petrol.
13-10-2012, 07:45 PM
#20
base coat pics,
I was a bit dissapointed at this point as it did'nt look to good but Martin Logan (busyboy) assured me it would be better once the base coat/clear coat work together and he was right but I'm still not happy with it .......
I was a bit dissapointed at this point as it did'nt look to good but Martin Logan (busyboy) assured me it would be better once the base coat/clear coat work together and he was right but I'm still not happy with it
.......
13-10-2012, 07:46 PM
#21
It needs P2000 wet sanded and 3M Green top compunding and polishing to be finished properly.
Overall I'm happy with the job but the colour match is very poor.....I'll ponder on it a couple of weeks and decide what to do but I think it's going to have to be scotched off and painted again
13-10-2012, 07:47 PM
#22
Been to get some more paint mixed up.....it's got more silver in it and less tint.
Will be starting to scotch it all off again this weekend.......
update***
15 December.
Current progress is - engine bay has been re-painted and is a good colour match but the finish is not as good.
Next decent weekend the car will be fully unwrapped for inspection and then decide what to do next.
In the mean time an order has gone into Ford for all the plastic clips with a grand total of........ Ł259 +vat
Also chrome plating has been collected after being away for 3 month and am I a happy chappy
Will be starting to scotch it all off again this weekend.......
update***
15 December.
Current progress is - engine bay has been re-painted and is a good colour match but the finish is not as good.
Next decent weekend the car will be fully unwrapped for inspection and then decide what to do next.
In the mean time an order has gone into Ford for all the plastic clips with a grand total of........ Ł259 +vat
Also chrome plating has been collected after being away for 3 month and am I a happy chappy
13-10-2012, 07:48 PM
#23
These also where a nightmare for him to do, although I bought new before I gave him them he said they had been etched and the buffer he had could not do small work, thought fair cop to him he never charged me any extra
The driveshafts took weeks to work and I mean weeks as they were terrible and no way was I prepared to buy new ones. So they have been machined and hand polished/copper plated before chroming
Now this bit (Prop Bearing holder) the bloke got confused with. He said it would be a nightmare to do and said he would have a go at it and if it was'nt looking good he would put it to one side. He's done a cracking job on it and he did'nt charge me for it, however,
he's polished up the wrong side So it'll be put it for shot blasting and powder coating
13-10-2012, 07:50 PM
#25
Recieved a delivery from Car builder Solutions today, though I'll not be using the brake pipe (as I'll be ordering up the Green stuff from Ford).
Thought I'd take the opportunity to show you peeps what else I already have to go on
Heat mat, adhesive and I brake pipe bender
Brand new genuine Ford rear calipers
Everything I need for the filler neck and tank,
One new and one old/powder coated fuel pump cradle, been there a year needs a polish
and my new Brake pipe Flareing tool I bought last month off the Snap on man Ł50 old stock
and a couple of spares to go with the 9 I have in the garage,
Thought I'd take the opportunity to show you peeps what else I already have to go on
Heat mat, adhesive and I brake pipe bender
Brand new genuine Ford rear calipers
Everything I need for the filler neck and tank,
One new and one old/powder coated fuel pump cradle, been there a year needs a polish
and my new Brake pipe Flareing tool I bought last month off the Snap on man Ł50 old stock
and a couple of spares to go with the 9 I have in the garage,
13-10-2012, 07:53 PM
#28
XuPicked the bottom end of the engine up on Sunday.
It's had new,
Mahle Piston rings,
Mahle motorsport Bearings,
Shells,
Light skim,
polish up,
Front Crank seal,
Rear crank seal,
Genuine Cosworth oil pump,
Block re-painted Black.
Only awaiting the head which is to be,
de-coked (exhaust side)
New valve guides
Valves lapped back in
Valve stem oil seals
Bearings/seals,
Acid bathed to clean it up,
all studs removed,
can't think of anything else
It's had new,
Mahle Piston rings,
Mahle motorsport Bearings,
Shells,
Light skim,
polish up,
Front Crank seal,
Rear crank seal,
Genuine Cosworth oil pump,
Block re-painted Black.
Only awaiting the head which is to be,
de-coked (exhaust side)
New valve guides
Valves lapped back in
Valve stem oil seals
Bearings/seals,
Acid bathed to clean it up,
all studs removed,
can't think of anything else
Last edited by Cossy Mike; 30-07-2013 at 03:50 PM.
13-10-2012, 07:55 PM
#29
Some little bits arrived today
Not sure how long the plating will last on these so I'm going to leave a couple outside for a number of weeks,
Nightmare finding these, Ford can't get the studs any more and I nearly got fleeced on Ebay but managed to do a chargeback via Paypal.
The Mrs wasn't best pleased when she seen the receipt
I'm going to give this a go on the head maybe this weekend or next. If it does the job I'll use it on both of the diffs.
Not sure how long the plating will last on these so I'm going to leave a couple outside for a number of weeks,
Nightmare finding these, Ford can't get the studs any more and I nearly got fleeced on Ebay but managed to do a chargeback via Paypal.
The Mrs wasn't best pleased when she seen the receipt
I'm going to give this a go on the head maybe this weekend or next. If it does the job I'll use it on both of the diffs.
13-10-2012, 07:56 PM
#30
3 different company's to receive these,
The all important Stainless steel A4 - 80 grade for the rear beam and diff
the only error in the whole order (should have been flanged)
Well that was Ł360 well spent :doh:
and I wish my snap-on man would'nt keep calling by my work or I'd have a few more bits
The all important Stainless steel A4 - 80 grade for the rear beam and diff
the only error in the whole order (should have been flanged)
Well that was Ł360 well spent :doh:
and I wish my snap-on man would'nt keep calling by my work or I'd have a few more bits
13-10-2012, 07:57 PM
#31
Not too much progress really
I've bought a new pair of Genuine Ford engine mounts @Ł216 and etch primed them then painted them Satin Black.
Sold my old pair on ebay for Ł50 after 2 hours
Have to pick up my 10 metre Genuine Ford Olive Green Brake pipe soon,
I've put all the stuff I had into the Powder Coaters for Silver, will have that back maybe next weekend.
Going to replace the front crank seal with a Viton one as the new one that was fitted is plain Black and I don't trust it (just me being me)
This weekend, need to make up a template for the heat proof matt on the bulkhead.
Need to buff up the paintwork in the engine bay then I can bond it in place.
BIG THANKS TO DAVE MONSTER!!!! for supplying the Polished Vin/colour plates which came last week
Pics to follow tonight as Im at work now........
I've bought a new pair of Genuine Ford engine mounts @Ł216 and etch primed them then painted them Satin Black.
Sold my old pair on ebay for Ł50 after 2 hours
Have to pick up my 10 metre Genuine Ford Olive Green Brake pipe soon,
I've put all the stuff I had into the Powder Coaters for Silver, will have that back maybe next weekend.
Going to replace the front crank seal with a Viton one as the new one that was fitted is plain Black and I don't trust it
(just me being me)This weekend, need to make up a template for the heat proof matt on the bulkhead.
Need to buff up the paintwork in the engine bay then I can bond it in place.
BIG THANKS TO DAVE MONSTER!!!! for supplying the Polished Vin/colour plates which came last week
Pics to follow tonight as Im at work now........
13-10-2012, 07:57 PM
#32
Small update,
Old ones,
New ones from Ford, I was a bit disappointed at the finish of the new ones, there not even painted fully and the bottom is bare metal
A quick etch prime, 2k primer and Satin Black and they look like this,
I think I should have just painted my old ones up
Old ones,
New ones from Ford, I was a bit disappointed at the finish of the new ones, there not even painted fully and the bottom is bare metal
A quick etch prime, 2k primer and Satin Black and they look like this,
I think I should have just painted my old ones up
13-10-2012, 07:59 PM
#34
I picked my front diff up from the blasters yesterday and was planning on painting it up along with the rear diff.
However After taking the diff plate off to inspect the internals just in case I was met with this,
So it was out with the spanners,
The whole thing has to be stripped down so I can flush it out and clean out the sand/grit :doh:
Most of today being spent on this and sourcing all new oil seals and o ring from Ford,
Really pleased how it all came out, but it was so time consuming, here's hoping we have a nice sunny day soon so I can get the casing's painted up,
However After taking the diff plate off to inspect the internals just in case I was met with this,
So it was out with the spanners,
The whole thing has to be stripped down so I can flush it out and clean out the sand/grit :doh:
Most of today being spent on this and sourcing all new oil seals and o ring from Ford,
Really pleased how it all came out, but it was so time consuming, here's hoping we have a nice sunny day soon so I can get the casing's painted up,
13-10-2012, 07:59 PM
#35
Small update, I've sourced a pair of Viton seals for the front diff from MSD.
Front diff re-assembled and finished paint - Needs stainless bolts polishing for the plate and oil seals fitted and it's done.
New Uprated diff mount landed yesterday - Needs bolts and spacers Zinc plating.
Rear diff finished paint - Needs oil seals fitting and output flanges painting in Black.
Not sure whether to use polished stainless bolts on the rear diff plate or paint the originals up Gloss Black. I'll do both and take pics and you lot can help me decide :thumbsup:
Backward step with the Engine cradle, fuel lines, inlet plenum, oil filter carrier and engine arms from the powder coaters.....
I've been ripped off again!
The quality of the work is shockingly bad, there's bubbles everywhere and the colour is the wrong shade of Silver.
My thermostat housing has been lost.
I'm not going to bother with anymore work from powder coaters and blasters I'll do it all myself from now on
Front diff re-assembled and finished paint - Needs stainless bolts polishing for the plate and oil seals fitted and it's done.
New Uprated diff mount landed yesterday - Needs bolts and spacers Zinc plating.
Rear diff finished paint - Needs oil seals fitting and output flanges painting in Black.
Not sure whether to use polished stainless bolts on the rear diff plate or paint the originals up Gloss Black. I'll do both and take pics and you lot can help me decide :thumbsup:
Backward step with the Engine cradle, fuel lines, inlet plenum, oil filter carrier and engine arms from the powder coaters.....
I've been ripped off again!
The quality of the work is shockingly bad, there's bubbles everywhere and the colour is the wrong shade of Silver.
My thermostat housing has been lost.
I'm not going to bother with anymore work from powder coaters and blasters I'll do it all myself from now on
13-10-2012, 08:00 PM
#36
Cracking on with it big time now, been doing brakepipes in engine bay, heatproofIng on bulkhead.
Abs block reassembled and servo refitted, pedal box back in.
Bought Ahmed baylor springs, rear arms are now complete along with rear beam and poly bushed with power flex items.
Gearbox checked over an fitted with 3 bearings and 3 seals, all painted up and drying as I type this!
3 boxes of Yellow zinc to sort through.
Genuine Ford clutch kit arrived from Woodford garage last week, the engine and box is ready to go back in over the next couple of weeks.
Can't think of anymore, didn't take any pictures :/
It's looking mighty nice I have to say
Abs block reassembled and servo refitted, pedal box back in.
Bought Ahmed baylor springs, rear arms are now complete along with rear beam and poly bushed with power flex items.
Gearbox checked over an fitted with 3 bearings and 3 seals, all painted up and drying as I type this!
3 boxes of Yellow zinc to sort through.
Genuine Ford clutch kit arrived from Woodford garage last week, the engine and box is ready to go back in over the next couple of weeks.
Can't think of anymore, didn't take any pictures :/
It's looking mighty nice I have to say
