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My white 4x4 sapphire cosworth re-build

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Old Nov 20, 2016 | 04:40 PM
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Default My white 4x4 sapphire cosworth re-build

Hello everyone, a bit new to posting on sites like this, but here goes!

About 3 years ago I purchased my first cossie, a black sapphire 4x4 facelift. I bought it cheap because it was a bit rough underneath. I used it and enjoyed it until it ran out out tax and MOT in January 2016. Mechanically the car was spot on, having had the engine re-built by harvey gibbs (if I remember correctly) and all the electrics worked which I understand is unusual lol!

Whilst I had it on the road, I had time to give the car a good assessment, and I decided that it was too far gone to repair - most panels would have needed replacing, so I bought a white 4x4 shell from Gary at rsclassics and a rollover jig from a company online, and so I stripped the shell done completely bare and started again, using the running gear from the black one.

I have documented this project with pictures when I have remembered to take them, so I will post them as soon as I work out how. Do I need to upload them to photobucket, then copy and paste them?

Thanks in advance guys, hope you enjoy the pictures..............
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Old Nov 20, 2016 | 06:20 PM
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Upload to photobucket and at the right hand side of the screen copy the IMG code.


Single left click over the code itself copies it.


Paste this into your post on here and all is good
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Old Nov 20, 2016 | 07:43 PM
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Ok here goes
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Old Nov 20, 2016 | 07:45 PM
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Old Nov 20, 2016 | 07:46 PM
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best of luck with the resto mate
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Old Nov 20, 2016 | 07:47 PM
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Old Nov 20, 2016 | 07:49 PM
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Old Nov 20, 2016 | 07:51 PM
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Old Nov 20, 2016 | 07:53 PM
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Old Nov 20, 2016 | 07:55 PM
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Old Nov 20, 2016 | 07:57 PM
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Old Nov 20, 2016 | 07:58 PM
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Old Nov 20, 2016 | 08:00 PM
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Old Nov 20, 2016 | 08:05 PM
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Old Nov 20, 2016 | 08:07 PM
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Old Nov 20, 2016 | 08:09 PM
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Old Nov 20, 2016 | 08:12 PM
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Old Nov 20, 2016 | 08:14 PM
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Old Nov 20, 2016 | 08:16 PM
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Old Nov 20, 2016 | 08:17 PM
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Old Nov 20, 2016 | 08:18 PM
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Old Nov 20, 2016 | 08:24 PM
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Sorry for the crap quality pictures, they were taken on my phone! So that is how far I have got so far, hopefully on the home straight now. Got the newly upholstered headlining installed today (thanks to gary at rs classics) and I started getting all the interior cleaned up ready to go back in.

Hopefully within the next month or so I should be ready to get it running again, but I have not done any wiring or plumbing under the bonnet as yet!

Let me know what you guys think, it has been quite a bit of work!
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Old Nov 20, 2016 | 08:35 PM
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wow, just....wow

wish I had the time, and skills....
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Old Nov 20, 2016 | 09:22 PM
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You have worked really fast on that, looks great


I really should work faster on mine
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Old Nov 20, 2016 | 09:36 PM
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Thanks guys, it has taken up quite a bit of my spare time, but as my workshop is only a few feet from my house, I can go out there whenever i like! Just noticed the photos aren't in order, they were before i uploaded them to photobucket!!
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Old Nov 21, 2016 | 08:50 AM
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Great project! That's a lot of hard work you put into that!!!
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Old Nov 21, 2016 | 10:00 AM
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Wow top job your doing matey. Nice to see another saff been saved.
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Old Nov 21, 2016 | 03:57 PM
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That's going to be a stunner, great work there!
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Old Nov 21, 2016 | 04:56 PM
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Done a good there m8,be back on the road before you know it.

Keep it up and keep us posted
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Old Nov 21, 2016 | 06:36 PM
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Hi Nick, great progress, this is the shell that Tim was telling me about then.

CheeRS.Lee.
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Old Nov 21, 2016 | 08:29 PM
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Cracking project, looking great.
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Old Nov 21, 2016 | 09:10 PM
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Originally Posted by 1374lee
Hi Nick, great progress, this is the shell that Tim was telling me about then.

CheeRS.Lee.
Hi Lee, yes it is mate, finally got round to posting the project lol, only about a year later!
Its getting there now, mainly interior and under the bonnet to connect up, hopefully it will then spring into life.

I see your cossie is coming on nicely mate, they love a good pampering don't they!! (and a wallet bashing)
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Old Nov 21, 2016 | 09:12 PM
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Thanks guys, really means alot to see peoples appreciation!

Once it is on the road (early next year) I hope to take it to a few shows in the summer, anywhere anyone recommends thats not too far away from the south west?

Also does anyone know the torque settings for the front and rear hubnuts?
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Old Nov 22, 2016 | 01:33 AM
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Looks great so far. A bucketload of time and effort but fair play to you as it'll be worth it when it's done
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Old Nov 22, 2016 | 03:16 PM
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Originally Posted by timewellnick
Hi Lee, yes it is mate, finally got round to posting the project lol, only about a year later!
Its getting there now, mainly interior and under the bonnet to connect up, hopefully it will then spring into life.


I see your cossie is coming on nicely mate, they love a good pampering don't they!! (and a wallet bashing)
Good to see you got around to posting up the pics Nick, you've done well there, that's an aweful lot of work you have got through there. Interior and under the bonnet to finish up, that's not bad at all then Nick.
Shows for next year local to you RS Combe (nr Chippenham, incase you wasn't aware) normally 1st week of July and Rally day again at Combe end of Sept.Further afield then Silverstone for Ford Fair, beginning of August and RS National Day at Donnington Park is on August bank holiday weekend.

Yes my car is coming along Nick, lots to do yet, will update as and when,waiting for my painter now to make a start.
Keep the updates coming, good to see the car evolve.

CheeRS.Lee.

Last edited by 1374lee; Nov 29, 2016 at 01:55 PM.
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Old Nov 28, 2016 | 09:46 PM
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More progress has been made, mainly on interior. This weekend I am going to focus on the engine bay and hopefully get it to the stage where it will run, but we will see (it never goes to plan lol).

I will post pics on sunday.

Does anyone have any measurements for the bootlid badges on the 4x4 cossie?

And, a job I forgot to do when I was putting the engine etc in was to install the exhaust downpipe, I assume you can do it without too much trouble on a 4x4? It is just a 3" stainless pipe
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Old Dec 3, 2016 | 04:57 PM
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Bit of an update, most of the interior is in, will post pictures tomorrow evening of what progress I make!

I have however realized that I need a new dash heater control unit (the slidey temperature thing) but for the facelift dash, has anyone got one I can buy as this is somewhat holding things up!!
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Old Dec 10, 2016 | 05:08 PM
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I have a question, I am putting the engine loom back into place under the bonnet, I have all the sensors connected apart from one which I can't see or remember where it is!

I assume its a coolant temp sensor wire for the gauge in the dash, small brown and white wire and it pushes on a threaded sensor like the oil pressure switch, but where is it? I have connected the blue sensor at the back of the head, I assume its near that as the wire comes out the loom with it?

Someone help please
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Old Dec 10, 2016 | 05:20 PM
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if its the same a 2wd its in the cylinder head on the left hand side just behind the cambelt cover.
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Old Dec 10, 2016 | 07:15 PM
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I don't think its the same as 2wd mate, the wire is only long enough to go about 5 inches either way of the blue coolant sensor at the back of the head, and I cannot remember where it came from lol
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