MA Developments Sapphire Cosworth 600+ HP 4x4
30-05-2015, 07:19 PM
#45
update with some pictures again of the 4x4..
Some new updates and pictures on the 2wd car will follow soon
Made some new longer exhaust studs for Marks twinscroll manifold on the lathe
Fitted into the head with some coppergrease
Then started fitting other parts / sensors to the head
Intercooler testfitting
New crankshaftsensor
We're using quaife thickwall frontdiff casing together with quaife ATB diff and thickwall plate
Managed to find a battery with square terminals so the Original bracket fits perfect
The Original brake lines were in good condition but I completely zincplated them and painted them green afterwards
Some trialfitting of the Aeromotive fuel system
Some new updates and pictures on the 2wd car will follow soon
Made some new longer exhaust studs for Marks twinscroll manifold on the lathe
Fitted into the head with some coppergrease
Then started fitting other parts / sensors to the head
Intercooler testfitting
New crankshaftsensor
We're using quaife thickwall frontdiff casing together with quaife ATB diff and thickwall plate
Managed to find a battery with square terminals so the Original bracket fits perfect
The Original brake lines were in good condition but I completely zincplated them and painted them green afterwards
Some trialfitting of the Aeromotive fuel system
20-06-2015, 07:59 PM
#47
I did put up some more pics of the restoration.
Some powerflex bushings on the front ARB
New 4x4 thermostat housing
We bought a Hart inlet to suit the engine spec
O-ring
I then did some milling on the inlet trumpets because the surface is not straight enough for using copper washers under the bolts.
Inlet also ported by Mark
All fitted up to the engine
I then made a custom oil drain pipe for the Borgwarner EFR turbo
Cutted the intercooler -> TB hose to the right size
New genuine Ford alternator and added some heatprotection as far as it would help
Fitted the Injector Dynamics 1000cc injectors together with the alloy fuel rail
Trialfitting the EFR turbo on Marks manifold and making some hoses and air lines to the right size
Alloy powersteering reservoir and also fitted the ignition coils behind it
We then needed to modify the downpipe to fit the EFR turbo, this is pretty basic by added some length and also fitting the V-band on a short new piece of pipe
Since it wasn't a 100% nice fit at the gearbox exhaust mount I made a new one and welded it to the exhaust
I did fit some heatwrap onto the exhaust manifold to protect the turbo air hose and alternator below
And some last overview pics and last things that we´ve done to the car
Fitted Original brake line to chassis with clip
Painted the rear propshaft
It was also time to fit new joints to the front propshaft
Aeromotive A1000 fuel system
After that it was MOT time and it passed without problems
At the moment we are solving a small oil leak and a other issue with the car after this we can take it to Mark for a final mapping session hopefully soon
Hope you likee the pictures above
Some powerflex bushings on the front ARB
New 4x4 thermostat housing
We bought a Hart inlet to suit the engine spec
O-ring
I then did some milling on the inlet trumpets because the surface is not straight enough for using copper washers under the bolts.
Inlet also ported by Mark
All fitted up to the engine
I then made a custom oil drain pipe for the Borgwarner EFR turbo
Cutted the intercooler -> TB hose to the right size
New genuine Ford alternator and added some heatprotection as far as it would help
Fitted the Injector Dynamics 1000cc injectors together with the alloy fuel rail
Trialfitting the EFR turbo on Marks manifold and making some hoses and air lines to the right size
Alloy powersteering reservoir and also fitted the ignition coils behind it
We then needed to modify the downpipe to fit the EFR turbo, this is pretty basic by added some length and also fitting the V-band on a short new piece of pipe
Since it wasn't a 100% nice fit at the gearbox exhaust mount I made a new one and welded it to the exhaust
I did fit some heatwrap onto the exhaust manifold to protect the turbo air hose and alternator below
And some last overview pics and last things that we´ve done to the car
Fitted Original brake line to chassis with clip
Painted the rear propshaft
It was also time to fit new joints to the front propshaft
Aeromotive A1000 fuel system
After that it was MOT time and it passed without problems
At the moment we are solving a small oil leak and a other issue with the car after this we can take it to Mark for a final mapping session hopefully soon
Hope you likee the pictures above
20-06-2015, 10:25 PM
#52
PassionFord Post Troll
Yeah wow love it 
13-07-2015, 09:30 AM
#57
I've found that life I needed.. It's HERE!!
CNC milling a new triangle shape hole for the plastic bumper fitting
Tacked into exact place and welded after that
Do you fancy making me 2 of these??
Tacked into exact place and welded after that
Do you fancy making me 2 of these??
31-07-2015, 04:45 PM
#59
sorry for the late reply mate. If you want I can make them for you just let me know
This weekend I'm making the 4x4 ready for MOT on upcoming Monday at Ford dealer.
We'll have another trip in the middle of August to Mark Shead and then hopefully we can have a final mapping session on the car
On the end of the year we'll continue with the 2wd to make it ready for 2016
25-10-2015, 06:50 PM
#64
We've been to the UK in August to map the 4wd Cosworth but unfortunately it didn't go as planned.
Mark did a very good job on mapping and also solved another problem so we could go ahead with fully mapping the car.
Went to the mapping road again but there the engine went bang.. Opened up the bonnet to discover a loose timing belt
The car was towed back to Marks workshop to find out that the M10 stud where the timing belt tensioner sits had come loose due the old thread beeing pulled out, just very bad luck.. It was all torqued up good so nobody's fault..
Mark did a great job on customer service by bringing and picking up us from the hotel since we needed to stay for the night and also bringing us to the car rental some miles away
We managed to get home after 2 days and the car was send back to Holland so we could take the head of ourselves.
Car MOT'ed in early August and ready to go
On our way to UK fueling up the car
In at Marks workshop ready to go out for mapping
Then in again after the timing belt had come off
Found 16 bent valves
After that a few weeks doing nothing to the car but last week we started with the thread repair in the head on the milling machine
Setting up the head on the bed to have a perfect straight drill into the head
Drilling
Tapping
Thread is now M14x1,5 to accept special steel 'thread bushing' which will cut itself in at the end of the thread and can't come loose..
On the picture it needs to go in further
Head will be off the Mark for repair hopefully soon.. We're looking forward to have this 4x4 ready for next year but also the 2wd
Mark did a very good job on mapping and also solved another problem so we could go ahead with fully mapping the car.
Went to the mapping road again but there the engine went bang.. Opened up the bonnet to discover a loose timing belt
The car was towed back to Marks workshop to find out that the M10 stud where the timing belt tensioner sits had come loose due the old thread beeing pulled out, just very bad luck.. It was all torqued up good so nobody's fault..
Mark did a great job on customer service by bringing and picking up us from the hotel since we needed to stay for the night and also bringing us to the car rental some miles away
We managed to get home after 2 days and the car was send back to Holland so we could take the head of ourselves.
Car MOT'ed in early August and ready to go
On our way to UK fueling up the car
In at Marks workshop ready to go out for mapping
Then in again after the timing belt had come off
Found 16 bent valves
After that a few weeks doing nothing to the car but last week we started with the thread repair in the head on the milling machine
Setting up the head on the bed to have a perfect straight drill into the head
Drilling
Tapping
Thread is now M14x1,5 to accept special steel 'thread bushing' which will cut itself in at the end of the thread and can't come loose..
On the picture it needs to go in further
Head will be off the Mark for repair hopefully soon.. We're looking forward to have this 4x4 ready for next year but also the 2wd
25-10-2015, 07:52 PM
#65
PassionFord Post Troll
Sorry to hear about the bad luck mate good to see it hasn't phased you nice work on the repair awesome saph this will all be worth it in the end I'm sure 
03-01-2016, 10:18 PM
#68
Top quality car, shame about the pulled out thread.
Although this is now probably back together, could you not drill/tap the head/thermostat housing for a fitting so the coolant pipe for the turbo is not two hoses of differing types with a multitude of fittings?
Looking forwards to reading future updates.
Although this is now probably back together, could you not drill/tap the head/thermostat housing for a fitting so the coolant pipe for the turbo is not two hoses of differing types with a multitude of fittings?
Looking forwards to reading future updates.
02-04-2016, 05:32 PM
#69
the whole engine came out end of 2015 and was send to Mark for inspection / rebuild..
Not much to update, Mark is waiting for the some of the last parts to complete the engine again.
In the meantime we bought Oppliger shortratio and standard ratio gearbox to fit when the engine is back hopefully soon.
Not much to update, Mark is waiting for the some of the last parts to complete the engine again.
In the meantime we bought Oppliger shortratio and standard ratio gearbox to fit when the engine is back hopefully soon.
18-09-2016, 07:06 PM
#70
the repaired engine will be ready for collection shortly from Mark so we'll be picking this up soon.
In the meantime also going to change some transmission parts which are bought a while ago. Hopefully the transmission is strong enough.
Ready to fit is a 9" inch Ford motorsport diff 3.6 ratio into a 2wd MT-Motorsport 6 degree adjustable beam.
2wd driveshafts/stubs in the rear will be used.
In the front there comes a R&D 7" inch diff 3.6 ratio
Also changed to bigwing sump
In the meantime also going to change some transmission parts which are bought a while ago. Hopefully the transmission is strong enough.
Ready to fit is a 9" inch Ford motorsport diff 3.6 ratio into a 2wd MT-Motorsport 6 degree adjustable beam.
2wd driveshafts/stubs in the rear will be used.
In the front there comes a R&D 7" inch diff 3.6 ratio
Also changed to bigwing sump
Last edited by Albertodelgado; 18-09-2016 at 07:07 PM.
18-09-2016, 07:49 PM
#71
PassionFord Post Troll
Just gets better
06-10-2016, 09:04 PM
#72
Fitted the 6 degree adjustable rear beam last week.
Cosworth 2wd 108mm stub axles to accept the 2wd rear shafts
Fitted the stubaxles
Fitting the 9" inch rear diff 3.6 ratio
Hopefully we can collect the engine from Mark in the weekend next week.
Then it's simply fitting the engine & box to the car again and doing some small mods to the car.
Plan is to have it mapped early 2017 when the weather is OK to make the trip to the UK for mapping session.
Cosworth 2wd 108mm stub axles to accept the 2wd rear shafts
Fitted the stubaxles
Fitting the 9" inch rear diff 3.6 ratio
Hopefully we can collect the engine from Mark in the weekend next week.
Then it's simply fitting the engine & box to the car again and doing some small mods to the car.
Plan is to have it mapped early 2017 when the weather is OK to make the trip to the UK for mapping session.
24-10-2016, 08:42 AM
#76
we've collected the rebuilded 4x4 engine from Mark Shead last weekend so it was ready to take the 4x4 shell out of the dusty corner again where it's been for more then over a year..
We'll be fitting the engine and gearbox upcoming week and then fit all the other parts to the car to make it ready for mapping session early 2017 done by Mark
We'll be fitting the engine and gearbox upcoming week and then fit all the other parts to the car to make it ready for mapping session early 2017 done by Mark
05-11-2016, 09:45 PM
#78
Advanced PassionFord User
Very nice buddy!
What clutch and flywheel setup are you running mate?
Cheers Paul
What clutch and flywheel setup are you running mate?
Cheers Paul
