ford sierra sapphire cosworth 2wd 1989

i bought this car as a bare shell in sept 2010 and then used all the parts from my rotten sapphire cosworth to build it up. before i started the rebuild i stripped the underside of all the underseal and checked for any areas that needed attention (one small patch at back of sill). the car was then undersealed and my mate began preparing it for the respray. it was then painted inside and out in the original mercury grey. while this was being done i rebuilt the engine with all new bearings, shells etc to freshen it up as it had done around 50k since it was built. while building the car no expense was spared and every bush, bearing and gaitor was replaced as to try and create as new a car as possible. i sourced a interior from a 50k mile car as my old interior had seen better days. the new interior is in very good condition with very small amount of wear to the drivers seat. all the running gear was removed from my old car and fitted to the new car which included nearly new gaz coilovers, rebuilt gearbox and diff and rebuilt standard calipers with uprated discs and pads. the car was then mot'd and put on the road march 2011. i then used car for weekend use and attending shows and covered around 10k miles until february 2012.

the engine was starting to get an annoying rattle when first started in the morning, so i took the engine out and sent it to joe stevens at bluesprint in essex. he phoned me a couple of days later to tell me that the noise was piston slap and that the bores would need boring out to .25 to get rid of it. i gave the go ahead for a full engine rebuild as there was no point putting it back together with worn parts. this included new cosworth racing forged pistons, oil pump, bearings, shells etc. once i had ran the engine in i took it back down to have the power upgrades fitted and mapped. it was previously running stg3+ around 340bhp on green injectors and t34.48 with the usual rs500 intercooler, uprated breather etc the car was then treated to grey injectors, .48 was swapped for .63 housing and was then mapped to run 2bar of boost giving just shy of 400bhp

i then realised the brakes were not up to the task of stopping the car very well so i bought hi spec monster4 brake kit complete with new discs and pads ( i have a spare pair of rotors too) which improved the braking no end. this caused a problem however as polished rs 7 spoke alloys did not fit over the brakes. I then fitted the 18in mo6 compomotive alloys

quick spec

engine
standard 4x4 head with bd14 inlet cam, 200block machined to except proper longstud conversion, wrc headgasket, .25 cosworth racing forged pistons with valve pockets, all new shells, gaskets, bearings etc grey injectors, 3 bar map sensor, t34.63, grp A breather system, mocal oil cooler, big turbo escort cosworth airbox with k+n panel filter (I also have a big kn cone filter if you like the chatter), baileys turbo damper, scorpion stainless exhaust, all samco hoses boost and water, baileys polished header tank, new 044 pump

transmission
t5 gearbox rebuilt around 30k ago, rebuilt diff 30k, new ap 6 paddle clutch kit 2k

other bits
hi spec 315mm brake conversion, rebuilt 2wd rear brakes, near mint 50k mile interior, boost, oil pressure and afr gauge, turbo timer with boost recall etc new fuel tank and fuel lines

since the new engine has been in it has covered around 5k and since the car has been built it has done about 15k

bad points
the abs doesnt work and the rear arches are bubbling in the usual place and the front bumper is stone chipped (paintwork might be done by time of sale). also it could do with a new fuel pump rewiring kit as the car wouldnt start the other week and there was no power getting to the pump so i made a loom myself from an amp wiring kit. Also the fans have been rewired externally from the fuse box but could really do with a proper msd loom

I loads of pics from the rebuild so if you would like some more please message me

im sure ive missed loads of stuff so if you have any questions please ask.

I'm not really bothered if it sells as I'd happily keep it so no silly offers please


thanks for looking
Billy