ajamesc

And some still rate t4's.

Caddyshack

Lol...I like your style. I have recently added a peachy 944 to the stable that is going to be my track car..lots to do first though.

I picked up the Cossie from Mark Shead today at MAD and my god what a difference a modern management makes along with new loom and the EFR borg...before it was quick but it was wait...boooost, change gear, wait a bit and boooost. Now it is just boost all the way and in every gear as soon as you hit the pedal, It was very rapid in low boost mode and I am not sure when I would need high boost as it was whipping through the gears and in to 5th pretty quickly. Havent even tried high boost yet which is odd for me as normally I would go max straight away...I might even save it as a treat for when the new box goes in.

It has a new exhaust system right through and I asked Mark to send the fabricators pics of the original T16 and they have got it pretty spot on, I asked for as quiet as possible and it really is quiet.

Mark Shead

Amazing isn't it.

Mark

Caddyshack

Lots of money but night and day difference, it is dial up to broadband difference and every cossie should have a Borg Warner.... I might buy an escort cossie now too!

Caddyshack

Well 400 plus of torque munched third gear in under 100 miles, that was low boost and being gentle

Rod-Tarry

Nice car !!
I came out of retirement to do your loom & now the slave driver has convinced me I have a few years left. So thanks .
I once owned a factory fitted Turbo Technics conversion on a 205 it was a nippy car with 185bhp so this little rocket ship is going to be very rapid .

Jay,

iTrader: (4)

You need a big tooth now chap so get the wallet out lol !! It does sound a good conversion Im sold anyway lol

smiley

Great project mate

Caddyshack

I also have a 205 gti with a Gti6 2.0 16v in it, it is 168bhp and I was able to keep up with my friends Cayman S on B roads and he certianly knows how to peddle. The rest of the car is factory standard apart from the front brakes.

The biggest issue I found with the Cossie was the speed diffrential with other car users under acceleration, I seemed to whip up behind them and struggle to slow the acceleration to a matching speed.

jontysafe

I had this issue with my Westie, thank god for decent brakes. You are going exponentially faster than normal cars and it takes a while for the old noggin to compute.

Having to suddenly pull in overtaking a column of cars can be interesting.

Whereabouts are you based?

Caddyshack

The westie is so light I imagine grip would be an issue on the brakes plus like my car it doesn't run huge wheels (mine are16's) so hard to get the best brakes under there even if you can get sticky rubber on there.

I am based near Guildford, Surrey.

Caddyshack

I have decided to invest in a set of Strongman Clifton Scissor Lifts for the garage to do the work on the Pug, this was a big step for me for home use as all in was around Ł2500 which is a long way towards the cost of the Oppliger Gearbox but I was fed up sitting under axle stands, scrabbling around and scared in case the car fell off in a freak accident.

So I am going to sink them in the garage floor but it has been lovely using them to strip out the gearbox.

I have found a fair bit of play in the rear diff hanger so as a precuation I have ordered a new one from MK in billet.

Whilst the prop shafts are out should I powder coat them or just paint them? Do people send them off to be checked / balanced / refurbed or no benefit???

smiley

All sounding great mate nice upgrade in the garage to, im going to freshen up my underside befor it all gets bolted up, i found a trader on ebay that remanufacture drive shafts 4x4 cosworth listed thier a very good price and uprated stronger

http://www.jandrcvjoints.co.uk/ford-escort-sierra-rs-cosworth-4x4-drive-shaft-uprated/

Caddyshack

Thanks for the link Smiley, bara said that I may need mine made shorter and he has someone to shorten them and rebalance but I will check out the link.?...checked and I have those. I am talking prop shaft and not drive shafts.

smiley

Doh! Sorry mate

Caddyshack

Trial pic



Just Trying out the new uploder

Since this pic was taken I have done away with the exhausts through the bumper as I never really liked them and Mark Shead found the system was holding back power so we had a new 4 inch made up with more silencers and the rear one done to match the T16 road car single exit, the system is really quiet which is something I wanted.

Caddyshack

Here is the rear box now, I have the bumper off to have the old exhaust holes filled and painted.

Jay,

iTrader: (4)

I like a quiet exhaust too especially when on long trips with a noisey box lol ! when you arrive after a couple of hours journey you spend the first 10 mins shouting at everyone lol

Caddyshack

Here it is sharing the driveway with my Steel Grey 205 gti, one of 300 made in that colour and I have just had a full repaint, this car is pretty much as it left the factory apart from the gti6 2.0 16v engine and brakes.

Caddyshack

New Rocker Cover and coil packs along with 1000 cc injectors, The rocker was done by Mick at Spray station and the silver is a paint so doesnt need a polish. I have since wrapped the rest of the loom. Rod did the vipec loom for me.

Caddyshack

Borg warner, I am now removing the Master Cylinder.

Jay,

iTrader: (4)

Ok I have started dribbling

smiley

What jay said lol love it!!

Caddyshack

Today I got all the bolts out ready to drop the gear box bar one left for tomorrow.

I also followed Marks advice and ripped out the anti lock brake system as I am going for a bias pedal box, this frees up a lot of room in the engine bay so I can get some heat shielding between the turbo and air filter and turbo and brake lines. I think that one the box is out I am going to drop the engine out and weld up any unused holes in the engine bay and then repaint the bay, the engine can be repainted when I have it rebuilt.

All of the wires in the pic above are abs related and therefore now gone. The late master cylinder is also out. I have found a company doing a pedal box for a 205 that bolts straight into the original mounts, I just need to see how this will match up to the reyland hydraulic clutch conversion.

I must say that the new ramps make it so much easier and safer to work on, I think the car must have been up and down ten times today whilst removing the braking system and gearbox.

maxest

iTrader: (1)

Love the cars.. But that garage is something else

Caddyshack

Thanks, it has another double tucked under the hedge that I use as my "workshop" plus hot and cold softened water outside for washing cars along with a karcher steam cleaner. I have sons sound system out there with streamed Internet with sub woofer....I spend miles of muh time out there but it is a good escape for me

maxest

iTrader: (1)

Think some more garage pics are in order..

Caddyshack

I have been fitting one of the MT Motorsport rear disc conversions and I had a few issues that were car related and not due to the kit, Mark has been really helpful and supportive.

First off we found the rear calipers were off a 2wd car on solid discs which was odd. Mark sourced me some 4x4 calipers but when I went to fit them they were 10mm out of lining up as if the discs was too large. Mark and I then spent a while on the phone measuring everything and it turns out my bearing carrier / hubs are only 12.9mm high whereas the 4x4 ones should be 13.9mm. I have no idea why mine are like this and where they are from? I am hoping that I can fit new 4x4 hubs and all will be good but I am a little worried as to why this was done....maybe it was to solve a problem with getting it all in the 205 shell.

I know the car was originally on escort Cosworth wheels so it could be related to that?

On a better note I bought a std 205 pedal box and cut it up to accept one of the reyland hydraulic clutch conversions, I will get some pics up but it all fits with the 205 servo and 405 master cylinder on the brakes as I have done away with the ABS unit.

Anyone know what my hubs might be from?

Tev

iTrader: (2)

Could they be off a xr4x4 or granada? ?

Not sure which but i have a feeling the beams are slightly different

800bhp

Thats a cool car. Liking the progress. Any idea how much it weighs?

costina

iTrader: (1)

Nice place,nice cars,nice garage.

Fair play to ya!

Regards
Paul

More pics lol

Caddyshack

I will get it weighed. I have stripped out quite a bit of weight so I think it is close to 1000kg

Marc sierra

iTrader: (1)

The rear hubs will be from a non-cosworth Sierra or Granada. They use 253 mm diameter discs in stead of 273 mm, so you're right that the pointing points for the caliper are 10 mm too far inwards. Those cars also use the same calipers as the 2wd cosworth (solid discs).

Focosmitch

iTrader: (1)

Just read this through, awesome project and great to see the car still going and getting the love it deserves!!

Hats off to you sir!!

Focosmitch

iTrader: (1)

Ps. Was that number plate once on a mercedes in the croydon area?

Caddyshack

The Ego plate?

No, the plate was on a bay window Vw van and I stopped the owner more than 20 yrs ago and bought it. It has been on a lot of cars but not a merc.

Caddyshack

Thanks for confirming, I thought the 300 mm discs looked monster next to the standard ones. It is a mystery why they are on there but I suppose in 1990 the Cossie parts were hard to source?

Focosmitch

iTrader: (1)

I see, there is a merc round my way that has a very similar plate!! Very ver similar as reads tye same, ego box

Caddyshack

I expect one is 30X and th other 80X? I would love to buy that one too if you ever see them to ask if it is for sale. My friend used to have just 70Y and 7OY on two different Porsches, it used to confuse a lot of people but the difference was zero and nought.

Focosmitch

iTrader: (1)

I will be able to ask for sure mate as its an old school mates dads car that had it!!