MA Developments Sapphire Cosworth 600+ HP 2wd
28-12-2015, 04:48 PM
#1
MA Developments Sapphire Cosworth 600+ HP 2wd
I have this car for a few years now it is a 1988 Flint grey 2wd Sapphire cosworth.
It came with a Pectel engine management, GT30 turbo and some other bits I didn't liked because me and my dad are also having a 4x4 Sapphire (topic 4x4 link -> https://passionford.com/forum/restor...00-hp-4x4.html) which is running an Borgwarner EFR twinscroll turbo and Vipec engine management and this combination is much better when Mark Shead does his magic to it.
That was the reason I decided to sell all the parts I didn't liked and install the same parts as the 4x4 Sapphire so we should see around 600bhp
The plan is to have this 2wd mapped this spring by Mark Shead
Below some pictures of the progress througout the last few months working on the car..
This was trialfitting of the EFR 8374 on the engine and on Marks twinscroll exhaust manifold a while ago
I then CNC milled some gauge frame plates to put some of the gauges into the Original clock location
I needed to do a thread repair on some of the exhaust studs so I made a jig to drill and tap straight into the head
Made some longer exhaust studs on the lathe to suit the exhaust manifold
Also modified the inlet manifold surface so it was level with the surface below and then I could seal it with copper washers underneat the bolts
I did want to have a engine loom with some proper Raychem DR-25 sleeving so after a lot of work the LHD engine loom was finished
Ignition connectors
This a picture of the garage together with the 4x4 on the right
CNC milled alternator lowering bracket so it would clear the twinscroll exhaust manifold
Heatwrapped 1 tube of the manifold since the turbo outlet hose is pretty close nearby although the hose is rated to high temps
WRC breather. This outlet will be connected to a custom tank from Pete Spec-R
Inlet manifold fully assembled together with Hart inlet, fuel rail and ID 1000cc injectors
Custom made turbo hanger plate from stainless steel for the EFR turbo.. This hanger replaces 2 of the locking plates which will hold the turbo main housing to the exhaust housing but the function is the same.
Will upload some more pictures of the progress soon
It came with a Pectel engine management, GT30 turbo and some other bits I didn't liked because me and my dad are also having a 4x4 Sapphire (topic 4x4 link -> https://passionford.com/forum/restor...00-hp-4x4.html) which is running an Borgwarner EFR twinscroll turbo and Vipec engine management and this combination is much better when Mark Shead does his magic to it.
That was the reason I decided to sell all the parts I didn't liked and install the same parts as the 4x4 Sapphire so we should see around 600bhp
The plan is to have this 2wd mapped this spring by Mark Shead
Below some pictures of the progress througout the last few months working on the car..
This was trialfitting of the EFR 8374 on the engine and on Marks twinscroll exhaust manifold a while ago
I then CNC milled some gauge frame plates to put some of the gauges into the Original clock location
I needed to do a thread repair on some of the exhaust studs so I made a jig to drill and tap straight into the head
Made some longer exhaust studs on the lathe to suit the exhaust manifold
Also modified the inlet manifold surface so it was level with the surface below and then I could seal it with copper washers underneat the bolts
I did want to have a engine loom with some proper Raychem DR-25 sleeving so after a lot of work the LHD engine loom was finished
Ignition connectors
This a picture of the garage together with the 4x4 on the right
CNC milled alternator lowering bracket so it would clear the twinscroll exhaust manifold
Heatwrapped 1 tube of the manifold since the turbo outlet hose is pretty close nearby although the hose is rated to high temps
WRC breather. This outlet will be connected to a custom tank from Pete Spec-R
Inlet manifold fully assembled together with Hart inlet, fuel rail and ID 1000cc injectors
Custom made turbo hanger plate from stainless steel for the EFR turbo.. This hanger replaces 2 of the locking plates which will hold the turbo main housing to the exhaust housing but the function is the same.
Will upload some more pictures of the progress soon
Last edited by Albertodelgado; 13-01-2016 at 04:56 PM.
28-12-2015, 07:10 PM
#4
Advanced PassionFord User
Awesome car and awesome skills! Keep the pictures coming.
28-12-2015, 08:38 PM
#6
PassionFord Post Troll
Perfect cossie and bloody well put together
Trending Topics
28-12-2015, 10:05 PM
#8
Advanced PassionFord User
Looks wicked buddy!!!
Cheers Paul
Cheers Paul
The following users liked this post:
ginner (29-12-2015)
30-12-2015, 09:46 AM
#14
Too many posts.. I need a life!!
Could you send me some more pictures of your loom? Still got the measurements? Love the Raychem sleeving, and I see you have LHD car which we also have in Norway. I've got the v88 as well and will be building the loom real soon.
Also, would really like to see how you mounted the VIPEC ECU. My Saph is almost identical to yours lol.
Also, would really like to see how you mounted the VIPEC ECU. My Saph is almost identical to yours lol.
Last edited by nixon_2wd; 30-12-2015 at 09:50 AM.
30-12-2015, 12:50 PM
#16
PassionFord Post Whore!!
Could you send me some more pictures of your loom? Still got the measurements? Love the Raychem sleeving, and I see you have LHD car which we also have in Norway. I've got the v88 as well and will be building the loom real soon.
Also, would really like to see how you mounted the VIPEC ECU. My Saph is almost identical to yours lol.
Also, would really like to see how you mounted the VIPEC ECU. My Saph is almost identical to yours lol.
Mark
The following users liked this post:
nixon_2wd (30-12-2015)
I hope you have more luck this time than with the 4x4.
30-12-2015, 06:09 PM
#21
10K+ Poster!!
30-12-2015, 06:46 PM
#22
PassionFord Post Whore!!
30-12-2015, 07:18 PM
#24
PassionFord Post Whore!!
30-12-2015, 08:54 PM
#25
thanks for the reply everyone.. will update with some more pics this weekend.
yeah whe had some bad luck with the 4x4 (topic can be found here -> https://passionford.com/forum/restor...00-hp-4x4.html)
Like Mark said while mapping the thread in head did let go, very painfull moment as everything went good but the good side was that we only have bent valves. Mark is taking care about that engine so it will be out for mapping again in 2016 also.
Although the thread in the head has a proper repair I couldn't resist making a cambelt tensioner locking plate for both cars.
For the 2wd it is ready. I modified the thermostathousing and the locking plate is different for each engine since the tensioner is not Always in exact the same place and I didn't want a large slot hole. The plate will be bolted to the thermostathousing.
yeah whe had some bad luck with the 4x4 (topic can be found here -> https://passionford.com/forum/restor...00-hp-4x4.html)
Like Mark said while mapping the thread in head did let go, very painfull moment as everything went good but the good side was that we only have bent valves. Mark is taking care about that engine so it will be out for mapping again in 2016 also.
Although the thread in the head has a proper repair I couldn't resist making a cambelt tensioner locking plate for both cars.
For the 2wd it is ready. I modified the thermostathousing and the locking plate is different for each engine since the tensioner is not Always in exact the same place and I didn't want a large slot hole. The plate will be bolted to the thermostathousing.
The following users liked this post:
knight7660 (05-01-2016)
08-01-2016, 03:20 PM
#32
a little update managed to finish the fuel system last week.. Aermotive A1000 fuelpump with AN-8 feed and AN-6 return together with Kinsler fuelpressure regulator
Positioning the fuelpump under the car with AN-10 feed
Kinsler fuelpressure regulator with sensor take-off
Bracket for the fuelpressure regulator and alu spacer
Fuel lines mounted under the car
Positioning the fuelpump under the car with AN-10 feed
Kinsler fuelpressure regulator with sensor take-off
Bracket for the fuelpressure regulator and alu spacer
Fuel lines mounted under the car
08-01-2016, 04:13 PM
#34
**RS COSWORTH**
Both sapps look brilliant 
12-01-2016, 04:02 PM
#36
thanks guys.. made some progession again last weekend finishing most of the wiring on the car.
Denso coils with some alu spacers made on the lathe
Fitted the coils
Then made a bracket for under the dashboard for all the relays
All labeled up
Some +12v feed from the battery to the relays
Fitted some of the wiring to the other pins on the relays. The main relay is switched by the Original +12v wire coming from the key and when the main relay is switched in switches on the other relays to supply the power to it's components.
Customized the genuine ABS ECU holder to accept the Vipec ECU.. I trialfitted it with the 4wd Vipec ECU unit so don't look at that
All fitted under the dashboard
Denso coils with some alu spacers made on the lathe
Fitted the coils
Then made a bracket for under the dashboard for all the relays
All labeled up
Some +12v feed from the battery to the relays
Fitted some of the wiring to the other pins on the relays. The main relay is switched by the Original +12v wire coming from the key and when the main relay is switched in switches on the other relays to supply the power to it's components.
Customized the genuine ABS ECU holder to accept the Vipec ECU.. I trialfitted it with the 4wd Vipec ECU unit so don't look at that
All fitted under the dashboard
12-01-2016, 07:27 PM
#37
PassionFord Post Troll
Just awesome mate 
13-01-2016, 05:14 PM
#40
cossie fan (unluckerly)
You want the best you have to go to the best. It will be an awesome car when finished