I have this car for a few years now it is a 1988 Flint grey 2wd Sapphire cosworth.
It came with a Pectel engine management, GT30 turbo and some other bits I didn't liked because me and my dad are also having a 4x4 Sapphire (topic 4x4 link -> https://passionford.com/forum/restor...00-hp-4x4.html) which is running an Borgwarner EFR twinscroll turbo and Vipec engine management and this combination is much better when Mark Shead does his magic to it.
That was the reason I decided to sell all the parts I didn't liked and install the same parts as the 4x4 Sapphire so we should see around 600bhp


The plan is to have this 2wd mapped this spring by Mark Shead
Below some pictures of the progress througout the last few months working on the car..







This was trialfitting of the EFR 8374 on the engine and on Marks twinscroll exhaust manifold a while ago










I then CNC milled some gauge frame plates to put some of the gauges into the Original clock location








I needed to do a thread repair on some of the exhaust studs so I made a jig to drill and tap straight into the head










Made some longer exhaust studs on the lathe to suit the exhaust manifold








Also modified the inlet manifold surface so it was level with the surface below and then I could seal it with copper washers underneat the bolts













I did want to have a engine loom with some proper Raychem DR-25 sleeving so after a lot of work the LHD engine loom was finished



















Ignition connectors







This a picture of the garage together with the 4x4 on the right





CNC milled alternator lowering bracket so it would clear the twinscroll exhaust manifold





Heatwrapped 1 tube of the manifold since the turbo outlet hose is pretty close nearby although the hose is rated to high temps





WRC breather. This outlet will be connected to a custom tank from Pete Spec-R




Inlet manifold fully assembled together with Hart inlet, fuel rail and ID 1000cc injectors











Custom made turbo hanger plate from stainless steel for the EFR turbo.. This hanger replaces 2 of the locking plates which will hold the turbo main housing to the exhaust housing but the function is the same.










Will upload some more pictures of the progress soon

 

Love the idea of the turbo hanger bracket, might have to copy that.

Looking forwards to the rest of your updates.

 

Awesome car!

 

Awesome car and awesome skills! Keep the pictures coming.

 

Said it before,your finish and cnc work is a work of art.
Keep the pics coming!

 

Perfect cossie and bloody well put together

 

Looks superb,what size is the exhaust housing?

 

Looks wicked buddy!!!

Cheers Paul

 

Alweer perfectie Stephan! Woorden schieten me te kort. Gewoon geweldig.
Deze blijf ik zeker ook volgen en hoop je Sierra 2wd zeker ergens eens te zien.

Keep going.

 

The picture with the 2 toys together is nice.

 

1.05 housing.

Mark

 

Absolutely fantastic work, looking forward to the results in spring.

 

Mooooooooooi

 

Could you send me some more pictures of your loom? Still got the measurements? Love the Raychem sleeving, and I see you have LHD car which we also have in Norway. I've got the v88 as well and will be building the loom real soon.
Also, would really like to see how you mounted the VIPEC ECU. My Saph is almost identical to yours lol.

 

Very nice

 

On the lhd cars I have done you have to add some length to the loom as the routing you need to run is quite a bit longer.

Mark

 

Very cool matey. Turbos have come along way in the last few years.

 

It's looking very good as always! I hope you have more luck this time than with the 4x4.

 

What happened to the 4x4?

 

The cambelt bolt stripped its tread at 7500rpm.

Mark

 

Why would it do that and is it game over for that engine?

 

Luckily he just went for a gearchange at that point and the engine came to a quick stop so amazingly it only bent the valves.

Mark

 

The cambelt bolt? Which one? Crank pulley, tensioner or cam pulley? At 7500 thats pure luck lol.

 

Cambelt tensioner stud pulled its thread in the head.

Mark

 

thanks for the reply everyone.. will update with some more pics this weekend.



yeah whe had some bad luck with the 4x4 (topic can be found here -> https://passionford.com/forum/restor...00-hp-4x4.html)


Like Mark said while mapping the thread in head did let go, very painfull moment as everything went good but the good side was that we only have bent valves. Mark is taking care about that engine so it will be out for mapping again in 2016 also.
Although the thread in the head has a proper repair I couldn't resist making a cambelt tensioner locking plate for both cars.
For the 2wd it is ready. I modified the thermostathousing and the locking plate is different for each engine since the tensioner is not Always in exact the same place and I didn't want a large slot hole. The plate will be bolted to the thermostathousing.

 

Wow. Serious builds both the 4x4 and this 2wd! Learning a lot from these threads

 

That locking plate is a good idea you can't beat over engineered

 

Wow great work. Would love to get my 3dr to this spec.
2wd and 600bhp.

 

Great work!

 

Great to see another M.A.D car going for 600+bhp. 2016 should be a good year for these big bhp cars.
Great looking project.

 

fantastic build fela work is amazing very impressed

 

a little update managed to finish the fuel system last week.. Aermotive A1000 fuelpump with AN-8 feed and AN-6 return together with Kinsler fuelpressure regulator


Positioning the fuelpump under the car with AN-10 feed









Kinsler fuelpressure regulator with sensor take-off



Bracket for the fuelpressure regulator and alu spacer



Fuel lines mounted under the car

 

Nice pretty much the same fuel system I'm running. Some real good work gone into this car

 

Both sapps look brilliant

 

Excellent work

 

thanks guys.. made some progession again last weekend finishing most of the wiring on the car.

Denso coils with some alu spacers made on the lathe



Fitted the coils




Then made a bracket for under the dashboard for all the relays




All labeled up




Some +12v feed from the battery to the relays



Fitted some of the wiring to the other pins on the relays. The main relay is switched by the Original +12v wire coming from the key and when the main relay is switched in switches on the other relays to supply the power to it's components.




Customized the genuine ABS ECU holder to accept the Vipec ECU.. I trialfitted it with the 4wd Vipec ECU unit so don't look at that




All fitted under the dashboard

 

Just awesome mate

 

WOW, what a car, simply awesome, you too Mr Shead




Regards

Pete

 

thanks! Yes Mark is doing an awesome job on the mapping and providing info to do things the right way..
Happy we've choosen him although it's always a long drive up there from Netherlands but it's worth it

 

You want the best you have to go to the best. It will be an awesome car when finished