Hi guys !

Here is a pregnant garage with a nice baby almost ready to go out



Before to have this one, I had another baby which I loved a lot









But on an icy winter, sideways have been to closed of the car...





So, I took off everything from the car : engine, gearbox, all interior parts and think about the future...

I'm sorry, but it has been impossible to take off the wheel in the trunk

So, few months after I bought a new 2wd, it was a car which wasn't running a lot, but I used it every weekend, changed all sensors and hoses, it was starting to run pretty well, but on a beautiful autumn day, the head gasket decided to blown on a straight line at 120mph...

Then, it was a good time to rebuild the old engine from my first 2wd, and put it in this one.

So I took the dead one out



and started to rebuild with the following specs :

Bloc 205
Bottom end balanced
Big wing sump + sump baffle
All ARP studs (crankshaft, con rods, head)
Cosworth pistons 7.2
High Pressure oil pump
Cometic head gasket
Head polished and enlarged
New valves and guides
BD10 and BD14 + double springs +vernier pulleys
Plenum AutoSpecialists
Injectors Siemens 83lb
Turbo T4 RS500
ProAlloy RS500 intercooler
ProAlloy water radiator
ProAlloy turbo after cooler


Bloc skimmed and piston-bore gap of 0.1mm lol it will smoke















I also did the plastigage for crankshaft and conrods, and I've been very happy about it as I have 0.05mm for every one



















The only thing now is that I have the piston going out of 1.04mm from the bloc because I skimmed it three times in the way to have a good surface aspect...Damn I will have to put a thick head gasket in the way to have a good squish

 

Shame about the moonstone saph, it looked lovely.

 

So the engine going in another Sapph then ?

 

Yes

 

c est beau ca mon nono

 

very nice my NoNo

 

Shame about you other saff.What a mess it looks

 

Look foward to seeing this progress fella!

Well done

 

Little up, I forgot last time to post my crankshaft pulley balanced :



And last weekend, as I started to change the fuel pump loom, I finally dismounted all the inside to clean everything and put back a lot of parts from my old cossie... (dashboard, trims, seats, headliner, etc...)

It was also a good time to remove the alarm, and to remove all the bad connexion on looms made by the old owner





Inside picture with everything fitted soon...

 

nice work my nono

 

Im sure theres a thread in general car discussion about those g19 baffels failing.
you might want to have a read before running it in your engine.

Car looks gorgeous in that colour

 

any news ?

 

Right now we have some nice winter days over there, it was a good time to work on the rear beam in order to dismount it totally to get a 6 degrees one, and also a good occasion to clean the underneath to check if there is no rust, and then to have to something nice to work on ! The result is not too bad for a 20 years old lady, and I'm pretty happy about the preservation state...

Here is some pictures :

Before :



After :



Soon, some more pictures

 

Could you not have pulled the dent out the old one lol! I bet you was gutted must have been a hard whack! Good luck with the new build

 

blimey that must have hurt

 

It seems sierras bend just a tad when they get a hit at the back! Good luck with the new one

 

looking nice,
quick question- do all lhd saphire cosworths have no electric windows in the rear?
or is there differant spec levels like the old rs turbo's etc?

 

As I know there was electric windows on all 4wd lhd and never on 2wd...

 

thanks, i never knew that

 

Car looked lovely in first few pics, then the smash was a shock.
Good luck with finishing.
Like the thread title

 

Long time I haven't had the occasion to write a bit in here...as I'm not all the time at home, it's hard to go ahead. But I've been recently able to work on, so here some pics, more will come.

Parts back from anodising :















Working on gauges loom :





Gauges from :

 

post more pics!!!

 

Many parts from engine has been sanded then black coated except the throttle body and the fuel ramp, received as it :







































And following the 65mm throttle body supplied by MK Motorsport, it tooks me a while to get it, but the job is awesome, thanks to MK !

 

I'm liking the throttle body very nice 70mm?

 

It's 65mm inside and take the original holes

 

Nice did it cost much?

 

Not sure, I bought it a while ago, but there is some info in here :

https://passionford.com/forum/trader...le-bodies.html

 

I had to rebuild fuel lines, as they were both mashed. I found a local supplier able to do the same one, and also ask the reproduce the plastic ones, here a pic of the job done.

 

Very nice, cant wait to see this one go back together!

 

I finally installed gauges into the car, I had them since a while.
What I did, is to take the dashboard lining from the old one, cut a part and past it onto the gauge mount plate, I'm pretty happy of the result.

 

looking good great work

 

Thanks mate

 

Coming on lovely mate!

Where are the pulleys from out of interest?

Cheers Paul

 

Actually this is Kent cams pulleys that I bought red, and I brought it for anodising, gives a cool finish.

 

Its looking really smart. Nice attention to detail too.

 

Love the gauge pod using proper dash

 

Hi mates,

I was thinking about to remove the ABS block and then install a pedal box with master cylinders for front and rear. I have seen the one at burton, but I don't know if it does exist others one ?

Which solutions have you fit ? If you do have some pics that would be great !

 

Very nice, it looks like it's original.