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Sapphire 4x4 fuel system/brake overhaul

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Old Sep 20, 2010 | 11:00 PM
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Default Sapphire 4x4 fuel system/brake overhaul

Its winter, winter is boring, so we need to invent things to keep us happy :P

Sooooooooooooooooooo...... Its time for an engine bay resto
Engine is coming out, few seals and gaskets will be changed and bearings etc checked (hopefully they are fine (6) ) The bay itself hopefully going to be stripped of everything and repainted. Any small parts that need recoated/replated will get done and everything will be slotted back together and look mint, well thats the plan lol.

Some photos

Some of the 'rebuild' parts -

Work begins -



Waxoil, going to be fun to get off lol


NO rot












Forgive the random photos, some are there for my refrence lol

Tomorrow, i'll hopefully get it jacked up and the front wheels off, which well let me remove a few other bits and some more wiring. then its pretty much ready for the big bits to come out. Hopefully i'll get away with leaving the dash in, but knowing my luck that will have to come out too.

Last edited by Paul_RS; Feb 11, 2014 at 10:00 PM.
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Old Sep 20, 2010 | 11:10 PM
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wtf you have carpet in your garage . Anyway you think it needs a resto? It looked great. Better then mine anyway
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Old Sep 21, 2010 | 10:36 PM
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There were wee bits annoying me, so i wanted to sort it once and for all



Some more photos from tonight, doesn't look like i did much, but i removed a load of fiddly brackets and freed most of the wiring loom - takes ages getting at some of the bits






Hope i can remember where these are supposed to go lol




Was also a bit preoccupied helping Mark with this -




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Old Sep 21, 2010 | 10:41 PM
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your going to be busy paul

are you painting the bay mate?
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Old Sep 21, 2010 | 10:42 PM
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Yeah, it all started with just changing the sump

Then decided i may as well tidy it up properly
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Old Sep 21, 2010 | 10:44 PM
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you must be back in love again paul lol
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Old Sep 21, 2010 | 10:56 PM
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Not really, jsut gives me something to do this winter
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Old Sep 21, 2010 | 10:57 PM
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any power upgrades paul?


a gt30 would be nice lol
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Old Sep 22, 2010 | 06:10 PM
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Lol not this winter, i'm happy enough with the performance at the mo, if i'm going more power i'll have to rebuild it to a new spec.
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Old Sep 22, 2010 | 07:33 PM
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Ghey update, Graham Goode Racing 3 port breather arrived today. Need to get adaptors for it to suit the -8, -10 and -12 hose i'll be using.



Anyone know of any decent smallish oil catch tanks i could use? I can't use the GGR one as it involves loosing the standard airbox I'm thinking something i can bolt up behind the arch liner to catch an oil that doesn't drain back to the sump from the breather.
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Old Sep 22, 2010 | 07:41 PM
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i think colins makes one that i seen in front of the battery
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Old Sep 22, 2010 | 07:52 PM
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Thats the one i've just replaced lol. You can see it in the very first engine bay photo i put up

Was looking one i can hide away out of sight in the inner arch - apparantly some for of rally cars had them there?
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Old Sep 22, 2010 | 07:54 PM
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all the best with it mate
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Old Sep 22, 2010 | 08:09 PM
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silly me i see it now.
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Old Sep 22, 2010 | 08:24 PM
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paul i seen a small specr one i think on suday that nestled in between the battery and the inner wing mate,i will ask the guy to send me a pic
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Old Sep 22, 2010 | 08:45 PM
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I'm after one that goes in the actual wheel arch, where that stupid carbon canister thing would normally be mounted, out of sight out of mind lol
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Old Sep 22, 2010 | 08:55 PM
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did you try pro alloy?
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Old Sep 22, 2010 | 09:04 PM
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why you ditching the one you have now paul ,


glad to see you and mark will be busy this winter lol


whats his plans for the escos , just a bufty up ?


beef
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Old Sep 22, 2010 | 09:25 PM
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Being a bufty lol. All my other tanks are GGR, so wanted the breather to match lol

Marks doing the same as me, but he's going to rebuild his engine as he thinks it needs it lol

Originally Posted by paddyrs
did you try pro alloy?
Haven't actually seriously investigated it, just something i got thinking about tonight
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Old Sep 22, 2010 | 09:34 PM
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i know what thats like am goen to get my car this weekend i hope its a staff 4x4 smokestone its 93 . am looken at intercoolers for it was on pro alloy there then looken at rad then fans then turbo cooler if i bought it all its about Ł1300 and am looken big breaks to dont know what ones ap's of hi spec shes goen to kill me
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Old Sep 22, 2010 | 09:44 PM
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paul wtf!!! your fond of a bit of work mate, i honestly thought your bay looked minty mint !!
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Old Sep 22, 2010 | 09:51 PM
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It will cost you a fortune lol, even if they don't break, you always buy bits and bobs for them! Smokestone is a lush colour

I love APs personally, for the money i don't really think you can get better brakes! I'm running a standard rad and have no cooling problems at all, even when i drive it hard. May be worth seeing if you actually need a new rad/ turbo cooler before you fork out for them?

PS sign up on www.ni-fords.co.uk, thats where we'd usually organise going to local shows etc

Originally Posted by DAN400
paul wtf!!! your fond of a bit of work mate, i honestly thought your bay looked minty mint !!
I just want it sitting exactly how i want, it wasn't that tidy to be honest, there was some crappy paint job action on the inner wing lol

Last edited by Paul_RS; Sep 22, 2010 at 09:53 PM.
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Old Sep 22, 2010 | 09:55 PM
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your not for national day by any chance? i need a block brought home.
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Old Sep 22, 2010 | 10:00 PM
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I'm not mate, sorry
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Old Sep 22, 2010 | 10:09 PM
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i think i am goen. kill two birds with one stone fly over get the car and drive to notional day drive home well there a ferry crossen before any one jumps in there
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Old Sep 22, 2010 | 10:14 PM
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[quote=Paul_RS;5102274]It will cost you a fortune lol, even if they don't break, you always buy bits and bobs for them! Smokestone is a lush colour

I love APs personally, for the money i don't really think you can get better brakes! I'm running a standard rad and have no cooling problems at all, even when i drive it hard. May be worth seeing if you actually need a new rad/ turbo cooler before you fork out for them?

PS sign up on www.ni-fords.co.uk, thats where we'd usually organise going to local shows etc


ya i think ill be geting ap's . am like a kid in a sweet shop when i go on any of them sites i think the intercooler will do for now the car is 375 bhp so could do with it
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Old Sep 22, 2010 | 10:20 PM
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Yeah try just a cooler first, then take it from there!

Good luck with picking the car up too mate
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Old Sep 22, 2010 | 10:27 PM
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thanx mate am like a kid waiting on santa
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Old Oct 3, 2010 | 03:36 PM
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Forgot to update this, so heres a loads of things in one post

Few more bits off and its on the ramp now.







Another small update, got the powersteering, brake and hydraulic clutch systems drained. Disconnected the last of my Fraser wiring loom, removed the header and power steering tanks. Removed the oil cooler and lines and drained the oil out of the front diff. Just working away at my own pace as there's no real rush to get it finished






Quiafealicious :P


Also decided to change the slam panel as some absolute wab had welded an amal valve 'bracket' (I use this term lightly lol) to the underside of it. No neat welding though, it looks like pigeon crap lol. I've a new geunine Ford panel in the attick, so may as well make use of it!
I think this project may have to include front suspension components too lol








Got a bit more done, pulled the Engine and ABS wiring looms back inside the car. Also cleaned a lot of the waxoil off. The bay is going to need a good powerhose to shift some of the hard to get to crap/waxoil. Painter has been to quote for painting the bay, fitting a new slam panel and redoing some of the seamsealer





Mmmmmmmmmmmmmmmmmmmm wiring :P

Two f*cked Cosworths
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Old Oct 3, 2010 | 04:12 PM
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you have been busy paul
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Old Oct 3, 2010 | 04:22 PM
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that bay looks awsome mate
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Old Oct 3, 2010 | 04:24 PM
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good work mate
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Old Oct 3, 2010 | 04:40 PM
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Cheers guys, should look far better when its painted
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Old Oct 3, 2010 | 05:30 PM
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looks mint
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Old Oct 3, 2010 | 05:48 PM
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Old Oct 3, 2010 | 06:01 PM
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Hi,

just out of interest, how are you going to put the engine/gearbox back in the car?
I see you have already refitted the crossmember to the car. Is this comming of again when refitting the engine?
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Old Oct 3, 2010 | 06:04 PM
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get the bay smoothed before paint

that will make it look so much better

all them holes that ford put there looks messy
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Old Oct 3, 2010 | 06:06 PM
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oh and your gonna have to do the underside
and back end next lol
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Old Oct 3, 2010 | 06:23 PM
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Lol, the thought had crossed my mind, but i don't want to go that far as i'll be scared to drive the thing

Originally Posted by v man
get the bay smoothed before paint

that will make it look so much better

all them holes that ford put there looks messy
I agree, but i kind of want to keep a standardish look


Originally Posted by YBJ
Hi,

just out of interest, how are you going to put the engine/gearbox back in the car?
I see you have already refitted the crossmember to the car. Is this comming of again when refitting the engine?
The cross member is just in to get the shell rolling again, it'll come back out to refit the engine as we'll be putting the engine/box in as one unit from below the car
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Old Oct 3, 2010 | 07:56 PM
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Oh my favourite saph is getting some attention

Keep up the good work Paul. Bay looked perfect in the 1st place mate.
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