I'll drive it for you, I don't mind! Lol

Like that, wheels look really good!

 

Time to start the engine rebuild!

 

Cool keep the progress coming.

 

You alternator bracket looks very unusual? Does the car have aircon?

 

Yes mate its the a/c, alt bracket. Big clunky item!

Got it stripped today.







Found that it had been balanced when it was rebuilt in the early 90's.
I think it might have an aftermarket flywheel. Anyone got pics of a std one?

 

Nice Brett, keep us posted mate

 

I got the head back from getting a freshen up today.
New exhaust valve guides, re-seat all valves and a light skim.





Inlet port


Exhaust port


Replaced the cam bearings and seals.
I will be just cleaning random parts and painting stuff until the bottom end is machined.
I will look at fitting my Bosch 044 and some braided line too.

Cheers

 

Nice work Brett, who have you got doing the machining for you? Someone local in Perth?

 

Hey mate.

I got the head done by a place called All Torque Engineering

The bottom end is getting done at Applied Automotive Engineering.

Applied have a bit of experience with cossies, and they have done a fair amount of work for me on my other cars. So I trust them!

 

Cheers mate, will keep the datails incase i need some work on mine.

 

Pistons arived on thurday. Took them to the machine shop friday.

They had crack checked my crank, its all good! Thats one thing I dont need to replace!





Now they can finish bores and balance everything up.

Not too long to go!

 

Ok. To my suprise I got a call today telling me the machining was done and to bring a huge wad of cash and come get it!

So the list of work was.

Block, tunnel bore mains, bore and hone .5mm oversize, very light skim of the deck.
The skim allowed me to go to a cometic mls head gasket.

Rods, Resize big ends, new small end bushes and balance.

Crank, After 24 years and 135000miles the crank was std std. And im glad to say it still is std std. All it was given was a light polish. The machinists were very excited about the cranks condition. It passed all there straightness and crack tests. They then balanced it up with flywheel,clutch, crank pulley ect . All good.

Here are the pics.

Block wraped in plastic! It will be running ARP main studs and head studs.


Rods with new ARP bolts, new little end bushes, resized & balanced




Std, Std crank, polished and balanced.


Now its time for cleaning, measuring, measuring, cleaning, cleaning and assembly! Probably more cleaning before assembly.
I will get into that next week.

 

Update.
Some good, some bad.

Well ive been cleaning and measuring. All bearing clearances are good. The pistons sit out the block a little high, but nothing a 60thou gasket cant fix.

Have a problem with the piston rings. One of the top rings has an end gap of over .913mm! Every other ring is perfect. Burtons have got onto Cosworth, so we will see how that goes. Thats going to hold things up a little!

So atleast the cranks in and blocks painted.

Got a new steering wheel too.









Now I wait for one piston ring!

 

Nice Brett, i like the steering wheel
Shame about the piston ring mate

 

Cheers Marco,

Yeah shame about the ring buts its under control. Cosworth are posting me a complete ring set today, so it shouldnt hold me up too much.

Im also getting a .070" head gasket so I will wait for that too. While I was ordering that I thought I may aswell get an alloy radiator, upgraded diff mount and some oil filters and spark plugs too....

No rush, just getting it done right!

The steering wheel is a localy branded wheel "Velo". They are made in Italy, I suspect from OMP. But they are around $90aud cheaper than the omp's/sparco's.

Cheers

Brett

 

Well the piston rings finaly arrived from Cosworth. Took a couple of weeks but they made it. The end gaps are alot better than the last batch thats for sure.

While I was waiting for the rings I got some other bits.
Diff mount, Airtec radiator and some random service bits.



Pistons in!








I also orderd a new intercooler and got a 4x4 intake.
Now I can bolt the rest back together and get it in the car!

 

Love them pistons, just a shame to put the head on.

 

The diff mount will make a big difference to how the car drives

Coming along really well!

 

Got a good days work on the engine today.

I built the head back up then got it all together again.

Will get it back in the car tomorrow.

 

I got the engine in and running today.
I fitted a new Airtec 70mm intercooler and Airtec 60mm radiator.
So I spent a bit of time sorting that out. Only problem is now there is no room for my Aircon condenser. So i removed it for now and will get something fitted up later.

Also had a oil leak from my oil pressure switch. So I will replace that too.
Should be good to go for a drive tomorrow.

Oil pressure was good and the tappets quiet. Well as quiet as cosworth tappets get So far so good!



Here's a comparison of a std 2wd intercooler and the Airtec unit.





Pic of it running!

 

beauty!, fair play to you

i know its built now but i would have gone for standard head bolts rather than the arp's

 

Cheers mate.

Yeah the head bolts/studs was a tough call. My last cossie cracked a block on std bolts.
So I left the call upto the guys that did the machine work. They look after/build many race cosworths over here. So arp's it is. The bolt holes were cleaned properly and studs installed as per arp's instructions. I guess time will tell!

I took it for a drive today and it all goes well. I replaced the leaking oil pressure switch so no more leaks from that.
Now I will clock up a few miles before an oil change and mabey a retune and some more boost.

Cheers

 

Nice mate, fast progress

 

Well done! Keep up the good work....

 

Well I have now done 850mile. Thats over 1300km, so the oil and filter has been changed and its ready for some more driving!

I have fitted an innovate wideband o2 sensor & gauge.
I made up a gauge pannel out of carbon fibre pannel. There is room for another gauge and my shift light which will go in soon. I will also replace those ones with some stack gauges too.

Ive had the rear door triangle trims carbon wrapped. Looks much better.

I drove around in stop start traffic the other day in 38'c heat and it didnt get hot. Thats good. The next week the temps are forecast in the high 30's. The lowest forcast is
37'c . It will be a warm xmas!








Have a good Christmas and new years!

 

Nice Brett, how is the innovate gauge?

 

Hi Marco,

The gauge seems to be good so far. Its showing the engine is a little rich. Which is what I assumed it was. I will get it dyno'd and compare it to the dyno's wideband. I dont have it wired in to log data either. So I wont be making any changes to the fueling just off the gauge at the moment.

 

Got a couple of things done.

Fitted the 044 fuel pump, only with std lines for now. The old connectors for the standard pump fell apart! Im glad I was getting ready to replace it anyway!

Got my shift lights in my gauge pannel.




And refitted my front strut brace.



Ive just been enjoying driving it again.
I dont care that a newer wrx or evo can be quicker. They dont have the soul of a cossie!

 

Looking good Brett

 

Peeps!

Not much of an update.

Ive fitted a 4x4 intake and have it booked in for a tune in a couple of weeks.

I recieved a package from marcosworth, ambers and a rocker cover. Thanks for that marco your a champ!

Here is some before and after pics with the indicator change. What do you think?

 

looks much better with the ambers on

 

Looks good Brett, put the wipers back on

Happy to help you mate

 

Haha Marco,

Wipers weigh too much! I need a trim with out the wiper cut out! Do they exist?

Thanks for your help, your a legend!

 

Yes mate the normal Sierra has the trim with no cut outs had one a few years ago

 

Cracking car .... And brilliant work mate

 

Thanks mate!

Its not to the standard of your car but it does the job for me!

Now Ive had the ambers on for a while I like them more.

I will be giving it a good going over this weekend ready for a full day of track work on the 25th. Thats after a re-tune after all the slight changes ive made.

Ive also orderd a new diff. I hope that will be here soon too!

 

Well I got some work done on the car today.

The last time I was at the track the standard viscous center wasnt doing much in the was of limiting slip!

So I spoke to Bara for a bit and then orderd a complete diff assembly complete with Gripper plated LSD and 3.9 ratio. Obviously new bearings and seals!







I cant thank Bara enough. I orderd the diff on the thursday before easter and it was deliverd to my door in Australia 2 weeks later!

Now im going to put some easy miles on it before a track day on the 25th of this month.
Then I will see how the traction has improved!
Its nice and quiet too!

 

Nice Brett still have to fit my Bara 3.6 diff

 

Come on mate! It only takes a couple of hours!

My legs got sun burnt while changing them over!

 

I know but i also need to change the beam and shafts as i'm still on 4x4 rear end