With some luck I became the new owner of Fastmaul's old Sierra RS Cosworth last summer it's past through a few different hands in the Merkur community before ending up in my hands in need of some TLC and a rear crank oil seal leak fix. Here are pictures of the progress I've made so far.





Out with the new seats in with the old!!







Jesus they didn't want the flywheel coming off did they?!?!







This is as far as I got last weekend turns out I didn't have any 3 square/spline bits for the head bolts in the shop at all...

 

Good man, resurrecting an old master ! All the best with the project, keep the updates coming !

 

Here is a much needed update of the progress




Fresh blasted parts ready for paint!







Con rod bearing #4 was getting ready to make things interesting.. thank god for that oil leak!


Yes we are even reconditioning the alternator! Upon taking the case apart we found both bearings were worn out



Alternator came out nice after paint and plating



Front calipers reconditioned and assembled!










Whats for dinner?


Gtypal coating inside the block is hard as a rock after curing at 125c for a few hours




Head is off to the machine shop for a valve job ned guides and valves too!


Front spindles reconditioned and packed up with fresh grease!



Rear calipers ready for assembly



surprise this weekend my uncle bought a lathe and needed a place to use it so he dropped it off at our shop!!


Video of us boring the block on our vertical mill
Video of the crankshaft being polished on a rig my dad made using fiber optic polishing film

 

Great work there. I hope the whole car will be treated like this and then we get all the pics of it all.

 

Thanks Lee! It is and i will post progress as the project comes along. Right now we are working on getting the engine back together and in the car. So I can enjoy it for a year or two until I can afford taking the body bare on a rotisserie take care of all the bumps and bruises then respray worth a fresh coat of moonstone blue.

 

Very nice work!

 

Strange looking engine mount.

 

Hi, nice proper work. Clean and fresh. I like it. But one thing interested me... what is that coating inside the block why you did that?

 

It's called glyptal its a anti oil coating that will keep things nice and clean. my dad knew about it and since he has been rebuilding engines since before I was born I said okay boss lets do it.

 

yeah I have no idea it has a bushing inside the cup area it goes together kind of like a control arm and seemed to be working fine when I purchased the car.

 

So the car came setup with this breather on it. Pro Alloy Breather
I am not sure if it was setup right or if other engine wear was the reason for what seemed like a significant amount of oil coming out the atmosphere vent.
One of the top pipes was plugged the other is connected to the crank breather outlet on the right side of the block. The large bottom pipe is vented to atmosphere and the small braided line is hooked up to the oil port on the left side of the block just above the oil pan. To me it seems like that would also be under crankcase pressure? Is this setup properly or is something a miss?

 

Well haven't gotten much work done lately thanks to all sorts of stupid stuff. Anyway this past weekend we finished reconditioning the valve cover..

 

Great job mate keep it up good to see an old members car living on and being treated well, i used to chat to fastmaul on here years ago, he still around? Whats he driving now?
On the breather set up post in the main forum in car related posts title it help cossie breather set up you should get a response thier dude

 

He is still around far as I know he's rocking a nice blue Merkur XR4Ti still with some cossie body bits. Not sure how much he reads forums anymore though.

Good idea on the breather thanks!