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Sapphire Cosworth 4WD restoration

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Old Oct 25, 2021 | 09:19 AM
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Default Sapphire Cosworth 4WD restoration

hello all, its been a long time since i have ventured on here ,ive been on and off for the last 20 years, some may remember me under a different name as i used to refurbish cam covers, anyway i still have the sapphire , just that since 2004 it hasn't actually moved
2 good friends of mine helped me take the engine out and strip it and put it back in , but i always had that niggle in the back of my mind that it wasn't right ,

so 2021 was the year to be , the car has been stripped once again ''real tears'' the engine is now with DP MOTORSPORT Dave Pritchard and the car goes for a full paint in march 2022 with Andy at platinum paintworks
ive been collecting parts for what seems an eternity for this car and hopefully 2022 should see it completed or very close,

anyway ill shut up now and let some photos do the talking



Last edited by RSGARETHW; Oct 25, 2021 at 09:30 AM.
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Old Oct 25, 2021 | 09:29 AM
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this was the car as it stood this year, not bad considering its been sat for 17 years , luckily in a dry garage






luckily i have a 2 poster ramp i have access to , so took the car there to be stripped








engine out again only for the 3rd time





stripped down as far as i could go ready to go to DP MOTORSPORT - go work some magic Dave

so the parts list has begun, i dropped the engine down with Dave and whilst there had a look over his esc cos, its a pure beast of a car and we discussed what i was after and as such came up with a list of parts id need and Dave set about stripping the engine over the next few weeks

well i hadnt even made it home the 3.5 hours and id had photos sent to me of it stripped , wasn't looking too good I'm afraid …..... more to follow

Last edited by RSGARETHW; Oct 25, 2021 at 09:32 AM.
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Old Oct 25, 2021 | 09:47 AM
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so before i go any further ill do a little update of what the plans are for the car and what i decided with DP motorsport and platinum paintworks

i spoke with Dave i wanted something reliable and quick so the below spec is what we have gone for , things will change in the next couple of years but for now this is how it will stay
power figure were looking around 500- 550bhp

new big wing sump and baffle from spec r
new oil pump
new mains and big ends
crank regrind
block cleaned, repainted and skimmed
10 x long studded - studs from Julian godfrey
WRC head gasket
new pistons with valve cutouts
bd14/bd16 cams
new cambelt and tensioner
new thermostat
head ported
new followers
double valve springs
new valve guides/seals
quaife pulleys
airtec inlet manifold
anembo fuel rail for Aeroquip fuel hoses
new loom from James @ auto Dynamix
borg warner efr 7064 twin scroll from Vince
running siemens 83lb for now

the list is endless and is growing all the time, we have replaced everything that could possibly fail, as the car needs to be reliable , a few more photos











Last edited by RSGARETHW; Oct 25, 2021 at 09:55 AM.
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Old Oct 25, 2021 | 09:54 AM
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so a few more updates with where the car is at the moment, the turbo will be being dropped off with Dave in the next 2 weeks along with reverse bracket for the inlet manifold, new fuel rail, alternator drop bracket, turbo oil drain pipe for the turbo and whatever else i buy, why didnt i just stick to 400bhp

the gearbox is currently at Pete doughty and hes awaiting the nod from me as to when to start making it straight cut

and im just debating if to go to harvey for a 6 degree rear beam or go to OMS both have good reviews

more pics










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Old Oct 25, 2021 | 10:14 AM
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Mega mate , welcome to the PF build crew .
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Old Oct 25, 2021 | 10:25 AM
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cheers mate, we will get there
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Old Oct 25, 2021 | 11:30 AM
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thats coming along nicely mate .

al these projects take a lot longer than we first anticipate
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Old Oct 25, 2021 | 02:15 PM
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ive only really started doing everything in the last 6 months, ie got a ruck of parts ive not even listed, air injectors, 6 pot AP'S new loom, all new clips, handbrake cables

the list is endless lol

im hoping its going to turn out just how i imagine
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Old Oct 25, 2021 | 04:02 PM
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what turbo did you go with and power are you going for gareth?
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Old Oct 25, 2021 | 04:22 PM
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hello mate , BW efr 7064 twin scroll
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Old Oct 26, 2021 | 10:40 AM
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This is going to be a mega build Gaz, cant wait to see the final results. Looking forward to getting some pics of ours together
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Old Oct 26, 2021 | 05:33 PM
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Will be like chalk and cheese dom lol

Be good to see them together , ill race ya
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Old Oct 26, 2021 | 08:39 PM
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Originally Posted by RSGARETHW;[url=tel:6826781
6826781[/url]]Will be like chalk and cheese dom lol

Be good to see them together , ill race ya
😂😂 There definitely won’t be any racing but I’m looking forward to you taking me out in yours
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Old Oct 28, 2021 | 06:25 AM
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looking forward to this build, dave pretty local to me, i have a few mates that are friendly with dave, his ecos is a sweet build
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Old Oct 28, 2021 | 10:25 PM
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Some more money spent this week
New anembo billet fuel rail with clips, reverse throttle cable bracket, anembo alternator drop bracket , wrc breather from kinzy motorsport and a Turbo oil drain which cost a small fortune

Never ends lol






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Old Oct 28, 2021 | 10:28 PM
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some nice parts mate
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Old Oct 28, 2021 | 10:40 PM
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Cheers James, did you ever aeroquip your fuel lines, just looking at regs now, heard good things about fuellab and aeromotive ones

Might pay torques a visit next week for a load of fittings
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Old Oct 28, 2021 | 11:02 PM
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i got my lines from advocult premade mate ,in black


I used a aeromotive fuel pressure regulator and mounted it on the chassis leg and then a short hose from their up to the rail

Last edited by james kiely; Oct 28, 2021 at 11:04 PM.
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Old Oct 29, 2021 | 10:02 PM
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Any pics mate?
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Old Oct 30, 2021 | 08:17 PM
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i will mate as early as i can.
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Old Nov 6, 2021 | 12:40 PM
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Great project will be a very nice car when done
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Old Nov 9, 2021 | 06:17 AM
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Cheers James, here hoping , breather got delivered last week off kinzy just waiting on a phone call now from anembo so I can go and collect the rest of the stuff , few more weeks then the engine should be going to harveys , depends how busy he is, not sure what dave has sorted yet
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Old Nov 9, 2021 | 12:17 PM
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Cool matey. Shame the car has been sat for that long. I would love to paint the underside of my saph but it would just be more cleaning ha ha.

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Old Nov 10, 2021 | 06:24 AM
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Originally Posted by Glenn_
Cool matey. Shame the car has been sat for that long. I would love to paint the underside of my saph but it would just be more cleaning ha ha.
thats why i'm scared to do the underside of my van project, haven't washed my van in a good 4 months, just find it too time consuming.

Love the project, looking forward to more photos.
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Old Dec 6, 2021 | 09:53 AM
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sorry for the lack of updates been a bit busy at the moment , went down to see Dave Pritchard at the weekend to drop the turbo off,drop bracket, fuel rail, wrc breather and more goodies

engine is getting there now and should be ready to collect next week , a nice early Christmas present for myself




and a quick one of daves looking all dirty lol


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Old Dec 11, 2021 | 11:46 PM
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Looking good
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Old Dec 19, 2021 | 08:59 PM
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Just need the cam cover refurbing now
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Old Dec 20, 2021 | 09:07 PM
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Wow that’s looking stunning mate
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Old Dec 21, 2021 | 08:22 AM
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Looking mega mate
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Old Dec 21, 2021 | 09:31 AM
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Looking good......
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