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Financial Disaster - Sapphire 2WD Restoration (?) from Germany
Hi all!
After joining this site sometime back in 2006 and having made (barely) any posts I decided to try starting a topic here (with the help of 4 Beers and now a glass of red wine since I ran out of beers..). I am greatful for any support, critical remarks and/or suggestions along my journey with my 1989 Sapphire 2WD. My ultimate goal would be to use it at a sort of daily driver during the summer and keep it in a decent and reliable condition (sometime far far away in the future), - but lets start at the beginning:
I could have been happy and satisfied with my EsCos I bought in 2014, yet in 2019 - god knows why - I started looking out for another Cossie to buy. Although never been a huge fan of Sapphires in the beginning I must have developed some interest in these models over the years. ultimately I came across a french registered 2WD which was for sale in Germany. The car was supposed to be stock with short fo 100k miles on the clock. On the pictures it looked gread for the price and when I drove out to meet the owner my brain stopped working and I just had to buy it...sort of..actually I just liked it and thought it was reasonably priced / cheap.
DISCLAIMER: I am not a car mechanic or the like - I also dont have a lot of technical knowledge nor a place to work on the cossie myself - so what could potentially go wrong, right?
Thats how she looked when I brought her home in late Summer 2019, pretty good for 7k Euros, right? (we will find out):
Ok now, what? First official action I had to take was to register the thing here in Germany. Whit a large part of the formalities resolved the TÜV decided that it was not going to be registered with an exhaust that was lacking a mid-muffler (???). So I found myself a EEC certified replacement exhaust on ebay, had it shipped and installed. Afterwards the car was on the road (even though only semi-legally as German cities mostly do not allow cars w/o a cat to drive around) with relatively little additional effort. Very nice! After driving her around very carefully (I am not the person who beats the shite out of his cars - my Escos has never seen 6.000+ rpm in 6 years) I noticed that the whole thing got pretty hot after just a few kilometres. Also the fans stayed on for c. 2 mins after turning off the engine when I just did some 30kms at moderate speeds over the Autobahn. Suspecting something wrong with the ratiator or coolant fluid I drove the car to my workshop of trust...guess what? Exactly! Head gasket! This is where the fun really started! With not many options at hand I took the hit and had a new head gasket installed:
After the money left my pokets, I had to get her registered in Germany - a thing - I learned - not too easy when you run an exhaust without a mid-muffler (?). Long story short, got myself an EEC certified exhaust from ebay (could I have gone for a mongoose? Yes! Would it have been a walk in the park with the TUV? No!). The rest went smoothly and I was able to drive it around town legally (more or less as in most citiey, cars without a catalytic convertor arent allowed anymore unless you get an history registration, which ultimately is the plan). So far so good - it it wasnt for the fact that even after 30 mins Autobahn with very gentle driving (c. 60 mph) the thing got really warm - Fans stayed on for at least 2 mins when I turned it off. I suspected something with the radiators and brought it to the shop....HEAD GASKET!
Left with no options I got this fixed (along with some small repairs / maintenance)...but the problem remained.
Last edited by striptease; Jan 27, 2021 at 09:33 PM.
Ok, with the head gasket fixed and some decent money gone again, I organised myself a place for parking the car and tried to arrange the interior a bit - by that I mean stripping down door panels and some minor interior trim. I also organised myself a few small parts such as headlight wipers (were missing on the car), a 4x4 hood in great condition (!), a replacement airbox (the other one was broken), some airbox clips (I found out that old VW Beetle clips are a perfect alternative to the cossie's and cost a whole lot less - available in new condition still) and other stuff...HOWEVER these were just minor things that I used to dance around one of the more serious problems at hand (by that time I found out that there were a lot of not so minor issues with the car - did I mention the new rear breakes already? dont think so...) ---> GEARBOX (need to figure out how to upload / link videos here to give you a nice 5th gear sound check) and DIFF!
Ist es schon Zeit für ein anderes Bier? Nice story to read, gonna follow this one.
Looks like you gonna need just a little bit more money than the 7k ...
5 gear is gone to? Can you get in al gears by shifting double?
Keep believing in it, in the end it's worth it. Kommt immer gut!
The price you have paid is pretty low for a Sapphire Cosworth but unfortunately as you are now finding out you will need to spend a fair bit on it to bring it up to a good standard. Best of luck with it.
Could be a bit of a ball ache I guess buying cheap and then having to get repairs done so soon... however, You could have shelled out 3x the price and still had to do the same repairs. Keep the updates coming though. For what its worth, I paid 25k euro for a 1992 Escort Cosworth last year which is low. It does need paint and other odds and ends, but I would rather get it done myself to be fair then I know.
Sorry for the delay in updates but I try to post them as fast (or as slow) as they come. Still need to figure out how to upload the gearbox soundtrack video (I recently switched mobile phones, might be that this is lost - in that case trust me, it soudned TERRIBLE in all gears - I was able to shift into every gear but esp. in 4th and 5th when the speedo hit 80 kmh or plus the whole thing started "singing". I think in the end i was able to attach it!). Also thanks for your replies so far - on the matter of money (which in Germany is always a touchy subject, but here I am on the internet, right?) - I do know that - especially given my lack of technicak knowledge - a Cosworth is not a poor man's car. Yet, since I am also not a millionaire or the like I will never put a 25k engine in that thing - I'll just try to find a reasonable way to bringing that Sierra from "close to desaster" to what I want it to be - a nice looking, gas guzzling 300+ hp daily driver that will teach all cyclists daring to stay behind it a lesson about the good old days (this is to you, Greta ) Having said that I am also not thinking too much about opportunity cost or resale value (I bought my EsCos for 15k, invested at least the same amount again but what can I say, I JUST LOVE IT). So to cut it short, Cosworths for me are an emotional matter.
Anyway, small update:
Drove the car to the shop (after I pumped up a flat tire - which actually was renewed already! - ) yet next to the nice loud gearbox and diff the drive was accompanied by some muscular exercise as the power steering apparently decided to quit service when the car stood still. So with the memories of my first car ever (Escort CL MK5 1.6l EFI - no power steering) I finally arrived at the shop. Then it was time to get the gearbox and the differential out. Looking OK from the outside for some 30 years old parts I was soon about to find out that they acutally were in catastrophic condition. So what to do? With nightmares about the only option being some Quaife parts to purchase for some money, I found a skilled and very helpful chap in our German Whatsapp Group. So I threw in the old stuff into the trunk of my Kuga and took in on a journey. The fantastic thing about that was that I was able to pick out a fully refurbished gearbox (while leaving my broken one and some extra cash) and bring it home the same day. The same chap apparently is able to also overhoaul my rear differential (thats a seperate matter as it turned out) Pictures tell more than an thousands words so let them speak:
Old Gearbox - ok from outsinde, f***** up on the inside Refurbished unit - Thanks to T***** - what luck that I found you! Diff pre-refurbishment, did not look good at all Diff after some work - housing is still at sand (?) blasing shop, hope to get it back whithin 2 weeks, thanks again Mr. T
Thats the old thing from underneath (1 of 2) Thats the old thing from underneath (2 of 2)
Off topic:
The EsCos <3
So with being sort of on track with the gearbox and the diff, next thing is the steering (small parts like silicone hoses and header tank already ordered but not worth mentioning yet).
Hmm - seems that my last update got stuck somehwere. Is it possible that it just takes longer for posts with images / video uploads to be released or do I need to write it again?
Hmm - seems that my last update got stuck somehwere. Is it possible that it just takes longer for posts with images / video uploads to be released or do I need to write it again?
Im afraid your last update has been lost. That sometimes happens when you press submit and the page does not want to load. Its very annoying and happened to me as well a few times. After experiencing that a few times I always select my text and copy it before submitting. If it then goes wrong I can always copy it back in.
But its very nice to see a new Cosworth project and I look forward to seeing your updates! Its really a shame that everyone seemed to have moved to Facebook these days. Last week I saw you are not even allowed to write Escort a Cosworth on Facebook anymore because Facebook thinks escort is an offensive word.
Im afraid your last update has been lost. That sometimes happens when you press submit and the page does not want to load. Its very annoying and happened to me as well a few times. After experiencing that a few times I always select my text and copy it before submitting. If it then goes wrong I can always copy it back in.
But its very nice to see a new Cosworth project and I look forward to seeing your updates! Its really a shame that everyone seemed to have moved to Facebook these days. Last week I saw you are not even allowed to write Escort a Cosworth on Facebook anymore because Facebook thinks escort is an offensive word.
haha tell me about it - passionford.com and ford-escort.de are blocked by my employer due to allegedly sexual content I'll start to re-write my post now.
@paulee Overheating not solved yet - will get gearbox and differential in an dhopefully have the steering fixed next up then will be the temperature issues as well as some boost problems I experience at c. 0.7 bar c. 10 psi
Ok, after my post apparently got stock in the middle of nowhere and 5 beers (0.5 litres) and seeing the soccer team I support losing again 3:0 I think I am ready for a second try. Let me recall where I left it:
Oh yes, the gearbox. So the car was registered and technically also driving around but I couldnt do much with it since both the gearbox and the differential made a heck of a noise when driving (adding to the temperature problems mentioned previously). I attach a small sound check (not the nicest video quality but you get a glimpse of the sounds I was getting when driving).
So after spending a little time in some german cosworth community whatsapp groups (SHOUTOUT to all the guys! The Cossie crowd in Germany certainly is not as large as in the UK but there are quite some fine and helping chaps out here too!), I found someone that was supposedly able to overhaul my differential and had an exchange gearbox for me (I had to let go off my broken one and some extra cash thought). But before I was able to have the parts disassembled (?) / removed from the Sierra I had to pump up 4 flat tires (suppsed to be new) after leaving the car for 6 weeks in the garage. *sigh*
ANYWAYS - this is what the status was (old unit out, new unit picked up in the trunk of the Kuga):
Ok Gearbox sorted out! I had to hide it from the missus meanwhile in my closet but now its at the shop waiting for being re-installed. Using this opportunity I also got some upskirt footage from the sierra - a bit dirty down there but for a 30 years old car quite decent I think! Really, really happy about the help I got - again big thanks (dont even know if the chap is reading this here)!!
So what about the differential? A couple of days later I receveived a not so nice message that the state of the gears (?) and other parts of the unit were technically garbage. The mate told me that he had some spare parts available but it was highly uncertain if these would fit in firmly - it was basically just one chance to try. Also he told me that due to private reasons we would not be able to work on it for the next two weeks. So I told myself to be patient (which I am absolutely not) and just wait for the outcome - just to find myself in from of the computer looking for refurbished or exchange untis already. Yet without much luck...HOWEVER - today I got some new messages in my inbox - I dont know how he did it but apparently he did his magic and got the differential to work again - and to look nice as **** as well! I will be able to pick it up next weekend and have it installed the week thereafter. Then hopefully the thing will be driving around a bit more smoothly again! Did I mention that during the last drive to the garage I had a flashback moment to my first car, Escort MK 5 CL? The power steering decided to quit its service apparently! Thats also whan I realised that I should really be getting back to the Gym once the whole COVID shite is over So next up: engine, temperature and/or steering oh yes and maybe I'll show you some more detailed pictuers of the body - a lot of work coming up here as well...i should just set the whole thing on fire, shouldn't I?
secret hideout for the gearbox Diff back then Diff back then 2 Diff now Diff now 2 Diff now 3 Diff now 4 The EsCos <3
Soory to hear about these problems. Cheap Cosworth to buy are never cheap to fix, so try to get the best you can if you are not able to do the work on you own. Best are: FSH, with known owners etc. Otherwise you have to know them well to check a potential buy
On the plus side it looks a cracker underneath, power wash will bring that up really nice id say
That's the point! Even the youngest Sierra Cosworth are about 30 years old now so spending money on it (even rebuilding a gearbox or an engine) is normal. But when this work is done properly it's still as good as a new car that has never been touched. but a welded bodyshell will always be a welded bodyshell, no matter how good it's been done.
Originally Posted by Kowalski91
Soory to hear about these problems. Cheap Cosworth to buy are never cheap to fix, so try to get the best you can if you are not able to do the work on you own. Best are: FSH, with known owners etc. Otherwise you have to know them well to check a potential buy
No Cosworth is cheap to fix. When planning to keep such a car and bring it in perfect condition you'd probably spend the same money on a good car as on a car that has some minor problems unless vital parts like the engine or the gearbox aren't fubar. As mentioned above, a good boyshell is very important and when the engine block and the cylinderhead are ok it's not that bad after all. Probably not worse than spending twice the money on a "better" car that just looks a bit better.
Enjoying this thread, with a beer. Nice reading.
Just take your time with it even if it looks like it's gonna take a whole lot of time...and money....
For the love of cars (read as we have an addiction) hang on and keep going.
About the Escort Cosworth, do you still have that to? Looks a clean one!
In der Zwischenzeit ein neues Bier trinken und es genießen, Freund.
Vielen Dank!
I dont know where the thread will take us ultimately, but lets see - about the escos, yes I still have it and it's basically my absolute luv (even though I develop more and more of a liking for the Sierra) - yet its not really a project so I dont think I'll be posting too much about the escort here.
Originally Posted by XR2
That's the point! Even the youngest Sierra Cosworth are about 30 years old now so spending money on it (even rebuilding a gearbox or an engine) is normal. But when this work is done properly it's still as good as a new car that has never been touched. but a welded bodyshell will always be a welded bodyshell, no matter how good it's been done.
No Cosworth is cheap to fix. When planning to keep such a car and bring it in perfect condition you'd probably spend the same money on a good car as on a car that has some minor problems unless vital parts like the engine or the gearbox aren't fubar. As mentioned above, a good boyshell is very important and when the engine block and the cylinderhead are ok it's not that bad after all. Probably not worse than spending twice the money on a "better" car that just looks a bit better.
I think that sums it up quite well - I did not buy the car with the aim to own a cossie at a bargain that woudlnt need much maintenance investment - yet from what has struck me so far (head gasket, read diff, gearbox, steering - currently being fixed -, temperature matters), that was quite a lot of issues in a relatively short time. But I still cling to my hopes of getting it into an OK status and use it as a sort of daily driver (during summer).
So far so good, yet mates - no major updates - I picked up the overhauled diff and I am having it fitted this week - I also shopped some spares to keep on the shelf for now (new old stock amal valve, ignition coil, turbo damper overhaul kitm new old stock yellow injectors and new old stock weber MAP sensor) as well as some items to put into the car - satin black power steering tank and swirl pot, new roose motorsport hoses and a 4x4 header tank.
No idea about what hoses to procure for connecting the swirl pot
Diffs mating
More to come as soon as sth. interesting to report is available - cheers!
Chaps - long time no post - update coming soon - dunno how many pics I will be able to upload but: diff in, gearbox in, new overhauled steering, new accesoirs (power steering reservoir pro alloy, new header tank (4x4) incl. silicone hose, new sensors (water, oil), new fans, new radiator incl. GG pipes, new fan loom, and new water pump. Seems like temperature issues and also bucking under full load / boost built up appear to be under control..and oh yes, new TÜV - more to follow soon
Today's beer of choice is Budweiser - the Czech Lager.
Ok where did we end up last time? Oh yes - after overhauled differential and gearbox have been sorted and installed the workshop also finally got my refurbished steering unit back and had it put into the car again. Only problem was however whilst spending some (4-6?) weeks in the workshop the radiator miraculously decided to reveal some leakage. Given that temperature is a thing with this Sierra (i reckon its a matter concerning 2WDs in general but as mentioned mine got freaking hot even after very gentle 30 kms on the Autobahn) I started to look for a new radiator and some other anciliary things. Result was new 4x4 header Tank incl. Roose Motorsport hoses, Graham Goode cooling pipes, some temperature sensors, pro alloy satin black radiator & fans, MSD Fan Loom, and new water pump (also GGR). Being sort of a victim when shopping online I also got myself Oil Filters, Fuel Filters, new HD ignition leads, plugs and distributor cap as I thought the buckling under full load could be a matter of the ignition (more on that later).
Then some more weeks later (car mechs keep on telling you they are always busiy dont they? My assumption would have been that once you got a cossie to fix, all other work ranks below but somehow they didnt share my view) I was able to pick the old thing up!
Temparature was under control, fans were running (even in the right direction i.e. sucking air through the radiator unit), steering was working and gearbox was A LOT quieter. Also the problems under load are now solved despite the fact that ignition related stuff I bought had not been installed (yet). Apparently this was more a boost related issue and after adjusting the boost via the actuator the car now builds up boost smoothly and holds it at 0.6 bar (8.7 psi ?). The car is supposed to be stock so I guess thats about rightish (dont know how accurate the VDO boost gauge is the previous owner had installed). Is everything fine now? Heck no! When lifting the throttle pedal there are still some noises coming from the front end of the car, the coating is shite and needs full respray, interior needs full makeover but I think next up will be wheels, suspension and related things. So stay tuned if you want.
- how much cleaning does you engine bay need? - Yes! Close to show-room concours already Steering unit looks cleanish-ok to me
So thats basically it for the update - I must say when I drove the car back home that day it was the FIRST TIME I drove it with more joy than fear (engine explodes, steering stops working during drive, gearbox explodes, rear diff dissolves accross the street, etc.) and I loved it. That really got me the motivation I need once in a while to keep on throwing money at this old piece of scrap metal!
Coming next - still some strange noises from gearbox (?) when lifting foot on thrittle pedal betweeen 40 kmh and 30 kmh in 1st and 2nd gear, Header tank cleaning exercise and more cleaning on the chassis...
Financial Disaster - Sapphire 2WD Restoration (?) from Germany
Nice story to read, gonna follow this one.
) Having said that I am also not thinking too much about opportunity cost or resale value (I bought my EsCos for 15k, invested at least the same amount again but what can I say, I JUST LOVE IT). So to cut it short, Cosworths for me are an emotional matter.
Last week I saw you are not even allowed to write Escort a Cosworth on Facebook anymore because Facebook thinks escort is an offensive word. 
.
