Hi All

Over the last few months i have been doing a minor restore on a cosworth i bought late last year. I bought the car with an engine issue, corroded/leaking fuel tank, bent/crushed fuel lines etc.

Below is the story of my car in a picture format.

When i bought her.











From there I sent the car to the body shop I use (Wood Brothers Garage Manchester) Brilliant painters. I had replaced both inner and outer sills on both sides replaced and both rear wheel arches.

How the car look when it was returned.







Photobucket has crashed on me so will add more pics later.

 

That looks well.Nice wheels too.

 

Disgusting....i'll give you Ł500 for it?

Wow that looks immense, totally loving that!!!!!!!
So does it run now, and what's left to do?

 

She runs better now thanks, Just need to have her set up now.

 

Once the car was returned to me I started working my way from the back of the car to the front replacing or renewing parts as i went.









The colour I decided to paint various parts in to contrast against the white of the car is a dark grey. The color is a BMW mini color which my cooper s came in.

I also changed both fuel lines due to them being crushed. I used 10mm galvanised piping with Earls ends.

Then i moved onto the brakes.







I refurbished all the calipers then sprayed them in galvanised paint. I replaced the handbrake cables, flexi hoses then flushed the system with dot 5 fluid.

 

I only read the thread title quick and thought somebody had put a cossie engine in a Morris Minor lol

Im sure that would be fun

Looks good mate, all the best with the resto

Steve

 

its a good looker!! best of luck mate.

 

its looking braw like keep up the good work

 

Very nice


Brian

 

Thanks everyone.

From here i decided to start under the bonnet. The engine had a misfire and water was mixing with the oil so i remove the head to investigate.







I found the water jacket next to number three piston had corroded and was spraying water onto the piston. see pics.

This is how i found the head upon removeal.



True to the last owners word the engine does seem to have beed modified looking at the ARP head bolts fitted and the porting of the head and IM.

 

Whilst the head was away being repaired i turn my attention to the heater matrix cover and the wiring loom.





With wanting the engine to look neater i move as much of the wiring loom behind the cover and fitted a 100 amp fuse holder to connect all the battery lives to leaving just the feed to the fuse and the starter motor feed on the battery. To see umteen wires bolted to the battery just looks scruffy.



Next came the engine mounts, gearbox mount and the rear diff mount. The engine mount were less than 12 months old but whilst i had the opportunity i decided to upgrade them.

 

Whislt waiting for things to happen id been bitten by the modding bug and had bought afew things to spruce up the engine bay, again Id sent them away to be painted in dark grey. Also i collected the matrix cover from the power coaters.











I decided to strip all the loom of its on tape, clean all the glue off the wiring and recover in fabric loom tape. The loom had been retaped in so many different places it just looked scruffy. Im glad i did because the injector feed wiring for number 4 piston had snapped and was just touching. very luck here i think!

Once i got the head back the rebuild started.









The car came with a RS500 (XS Power) intercooler and radiator which i rubbed down and painted in galvanised paint again. I decided to buy a fan wiring loom conversion kit due to reading on hear about the poor standard system and also upgraded the fans themselves to hi flow units which are lighter and thinner than the standard unit.



Before painting id refitting the intercooler and cut the exit pipe off and re angled the pipe to reposition inline with the swedish manifold then had the pipe rewelded to the intercooler, at that point i also had the dump valve fitting weld to the intercooler for neatness.

 

And here we have it.... A rebuilt engine. Id sent the turbo away and had it rebuilt by euro turbo's. Just a standard rebuild nothing special. Ive fitted an AFR guage into the dash just to keep my eye on things. Ive fitted a AFP reg with earls hosing and found a fitting for the water return from the separator at the on the timing cover to the expansion tank to save me from having to buy an alloy header tank which in all honesty Im not to keen on.







There she is, First time out of the garage in months. From there she went back into the garage for a full clay bar session, then tar remover, 4 x coats of autoglym and 1 x extra gloss. Pics to follow