Hi Guys

Some of you might remember i started a restoration thread not so long ago about my 3dr cossie. It was abit slow to start as there was not many pics and we all love the PICS so now im further into it i have decided to start another thread with more pics.

A mate of mine bought the car originally to restore but his other toys kinda took over and i managed to persuade him to part with it.
I was originally building an wrc styled escort cosworth with skyline running gear but sold it to fund this project. (Love the wrc escorts)

I had been out the scene for a long time but had a few cossies years ago and have had all sorts of cars since and still come back to a cossie (says something) I always wanted a 3 door and to strip it bare and start again but never had the time or funds. NOW I HAVE and im loving it

Any comments welcomed guys

This was it the day my mate picked it up:


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Then a few months down the line we dragged it out of his workshop:

To be fair it looks worse than it is, my mate is a perfectionist and because the wings were non gen he took them off.

Tucked up in my garage awaiting the resto


A few pics of it being stripped:



Well as always with these old fords it esculates quite quick. I new there was some welding to be done so i set about buying as many new genuine panels as possible and a rollover jig to do a proper job:


How sorry does this look for itself:



The rest of the running gear was filthy aswell, The car hasn`t been taxed since 2006 and the least they could of done was cleaned it before the tucked it away in its (DAMP) garage for 6 years

Anyway as i was getting all the underside ready for the new sills and arches to be welded in and all the stone chip off etc i got a phone from a mate "Wanna buy a new old stock shell" Now to be honest i had spent Ł1200 on parts already to do mine but when i saw the pics of the new shell and was told the price i had to have it.
Day we picked it up from Oakfields in Hook:

Brand new unstamped 909 cosworth shell with sunroof all original and not a mark or rust on it

Out with the old and in with the new as they say:


This has made life so much easier as dont get me wrong im no bufty and she will get driven hard but if im gonna do this its got to be right.

Up on the rollover jig ready to be started:



Just gonna post this lot up before round 2 to make sure the pics come up.

 

Just gonna try and make the pics bigger as im still abit new to all this photo upload stuff.

The engine just before it went off to be rebuilt.

Going for aroung 400BHP

 

great bonus with the new shell rich ,i will be locked on to this lol

 

Cheers James. got a load more pics but cant seem to make the pics bigger.

 

Well i managed to get some time to get the underside of the shell prepped resealed and stonechipped:

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Then i got the inside and outside prepped for primer:

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So nice starting with a new shell

Now its time for paint. Im only going to paint the underneath and insides as i want the outside done properly in a oven. I painted it first in diamond what and then realised who horrid this is, now i know alot of people would say keep it original but i had to do it in frozen white and i must be honest im glad i did!

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A bigger pic of the new shell before it was painted:

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I know the views people have on "reshelling" and i know what you mean but i have always wanted to build one myself from scratch and wasn`t keen on all the welding etc hence the new shell. This is a genuine cosworth but i want to build it how i want it hence there was no point in buying a concourse one to start with just to rip it apart.

Dont get me wrong you will be able to eat your dinner of this once finished as there will be no expense spared. It had only covered 80k so the trim is near on perfect

 

Looking good ill be following this keep up the top work

 

Far better to start with a mint shell than start weding a rotten shell Rich

I will keep an eye on this thread

BTW , Ian @ Oakfields is a great fella to deal with isnt he

 

Had a call from engine builder to say its all been bored, skimmed etc so come pic it up when i was ready to be painted:

Brief spec is going to be: Full rebuild with 0.5 oversized forged pistons with valve cutouts, Bd cams, Verniers, group a and arp everything except head bolts (Standard) siemens 55s, T34.63 poss gt30 with external wastegate, alloy rad and cooler and mapped by the right people

Block when i got it home:


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All painted up:

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Cam cover painted. Not bad for a builder :

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Head and sump all painted and got a delivery from Matt Lewis (top man) so ready to go back to engine builder:


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It looks that pretty i wanna keep it in the garage on a stand LOL

 

Looks very nice, id rather buy a reshelled car than a welded up rot box

 

Thanks Paul means alot coming from a man such as yourself. Ian is a top bloke he mentioned you two have a few deals

 

Nothing wrong with a reshelled car

 

Gona be a good one to watch

 

Gearbox was minging so powerwashed it with just about everyother item that came off it and started to paint all the bits.

Gearbox before and after:

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A customer donated there old garden shed to a good cause LOL:

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would be a minter when done, cracking new shell love it

 

All the suspension stripped and main bits sent to powdercoaters and i painted all the hundreds of small bits left :

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Jesus i never knew how many bits are on these things, Could i have a few more please:

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I was high as a kite for 3 weeks solid painting this lot

 

Inter cooler turned up the other day.

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Hmmmmmmmmmm Shiney

 

Looking good mate

 

Cheers Mat. Its all you lots fault LOL!!!!!!!

 

Thats about it at the minute guys as i only got it at christmas lol.

Next job is to start stripping the loom out of the old shell re tape it all and get that back in the new shell. Once thats done hopefully all the stuff will be back from the powdercoaters and then i can get it back on its wheels.

WATCH THIS SPACE!!!!!!

Any comments more than welcome guys

 

 

Nice, Where you get roll over jig from Rich?

Cheers

Paul

 

Looking good.

Keep the updates coming.

 

Ebay mate. Good bit of kit. I wouldn`t buy the self build one as for the extra money its not worth the hastle as i did this for my escort.

 

Cheers for the comments guys

 

Well if you wanna sell it once your done give me a shout

cheers

Paul

 

Ok mate i will bare you in mind but the old shell will be going on it once the new one is off so it might be a while LOL

 

Cracking work there.
Coming along nicely
Will watch with interest

 

Fuck me Rich, i better pick up the pace!

Not always been a builder, aye mate

Good work fella, looks sweet. Whats happening to the old shell? Ive always fancied doing a 3 dr 24v BOB.

 

Looks well mate.Cool project.

 

You better had mate, mind you ya cant rush perfection LOL.

Damn rumbled about being a builder! Ok so i may have painted the odd car now and again

Regards the old shell im not really sure yet. My fabricator is semi retired and said drop it off to him and he will weld it up for me so i might do that. Im gonna hang on to it until the other one is done and then see i think

 

Cheers Glenn.

 

this is top work mate, following this with interest

 

Well havent done much over the last few weeks as works gone nuts and still waiting for bits from Matt Lewis before i drop engine off to be put back together.

Also should have all the underside bits back from powdercoaters so can get it back on its wheels.

i did manage to get in the garage today and have a good clean up and sort out ready to crack on as it was a shit tip!

MORE PICS SOON!!!!!!!!!i

 

Also trying to make a decision on what wheels to go for

At the minute im looking at calibre vintage in 17s or comp mo6 old schools in 18s Maybe in graphite?

Any pics or input would be appreciated

 

Rich, in your collection of parts, do you have a spare front ARB and brackets?

 

No i dont bud. Are they different to a saff 2wd one?

 

Sorry mate, just noticed in this pic



Think thats a MT75 gearbox cradle.

A T5 one looks like this:



Unless im wrong and i have the wrong mount of course.