the story of my 88 cossie & engine rebuild/freshen up.

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19-08-2008, 07:17 AM

R5FORD

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the story of my 88 cossie & engine rebuild/freshen up.

i thought id start this thread as a insight to how my car has changed over the last year.

Since i was a baby all iv really wanted was a sapphire cosworth. my first word believe it or not was 'coffers' as i pointed at my dads cosworth

.. growing up i saw and helped my dad work on his 30,000 mile 2wd saph.i loved everything about the car, bbs split rims, leather interior, it was only running a stage 1 chip with a power engineering straight through exhaust but it was rapid, one thing i loved was the motor sport stripes it had

i soon started growing up and came to the age where driving was around the corner.. but we had to sell he car as we were all moving to australia

i refused to sell it but in the end we sold it to one of our god friends disco dave. i vowed to own my own cossie that would one day be a beast.

so for the time being i had forgotten all about owning a cosworth as i was settling down in oz and my sister was getting married in England in june (2007), then i thought it would be a good idea to look at bringing a cossie over so the hunt for the perfect saph was on. i found a ultra clean 2wd saph with only 18,000miles on the clock

we went to go and view it and it was everything i wanted but the price was a little to high.. the garage owner wanted 8,800 for it but i didn't want to pay that much.. in the end we left without purchasing it.. a week went on and my sisters wedding had passed so i had more time to look for a different cossie, i saw loads and loads but none of them caught my eye like the first one did, we took a 3 hour trip back down to the garage where the 18,000 mile saph sat and got the garage down to 8500 and we struck a deal and the cossie went home with me that day. it had the original dunlop d40 tyres on

which lasted the trip down home but as soon as we arrived the wire started showing through the rubber

..

i had to return to australia while my cossie sat at my grans house, it was booked in with pj motorsport for a stage 1 chip, tarox 330mm brakes, 3"exhaust system, bk racing wheels, yoko prada 2 tyres, full samco hoses and ford racing gauges.

this was the end result of what i thought was a decent powered car..

so my cossie was done

then my dad thought he would be driving it around instead of me and i said erm no chance

so then we decided to buy another one but this time a special one.. a rs500

i put a few posts up on here asking for a perfect rs500, and in the end we found one.. it belonged to steve off here he looked after it so well.. so my uncle and brother in law went down to steves and brought the car home with them..

so me and my dad were happy knowing we both had wicked cars.

they arrived in Australia and got complied by paul who is a very nice fella and helped us out alot ( cheers paul).. then it was just time to enjoy them. both cars got used everyday and not one problem.

Then passes a few months and im bored of the power

.. so as going back to england soon i though it would be good idea to go stage 3, so i collect a new l8 ecu, greens, t34.48 and a new closed loop chip from Stu at msd.. now all these parts are in the uk and i bring them on the plane with me

i arrive back in melbourne and fit all my new parts.. book the car in to get setup by the local who fine tunes all the porsches for the carrera cup.. get the car on the dyno and the intercooler to throttle body hoses blows off

then we get it back on and we achieve a nice 330bhp. a couple weeks past and then i start to get a smoke from my bonnet vents

my turbo had shit itself.. so it was taken off and sent to the local licensed garret turbo builder.. he tells me it has dies off oil starvation but i checked oil was coming through before starting the engine, so then we thought it may have shit itself when the i/c to throttle body hose came off but we scratched that idea as well as the car had driven fine for 2 weeks. the garret dealer then sets off to start building me a new turbo and asks if i want it roller bearing.. of course i say yes before seeing how different its going to be to my current turbo. so the turbos built and ready for fitment.. first fuck up is that its 10mm shorter

so it had to be lifted up with a spacer to avoid hitting the head.. this cured it hit the head where the damper sits so we had to cut out a section of the head

then we finally get the turbo on. then we try and get the exhaust on the back.. no luck again.. we had to take the exhaust off and weld in a 10mm spacer.. finally once everything has been welded and put back on it fits up. car goes for a setuo and gets a nice 350bhp

.. was happy with that for the time being.. time passes and the engine starts to get a bit noisy.here is how the engine looked then..

i then smash my bk racing wheels

and i considered going for comp mo's but in the end got a set of custom 3 peice wheels made up.. this is the end result of those..

then time came where i was looking through some old photos and thought about putting tiger stripes on my car just like my dads old one, so i order a kit from fordstipes and they arrived and a few weeks after i started putting them on..

and then after a few days the final result..

then as my car was finished for the time being i enjoyed it until i had to have 5 people in the car and the wheels were catching the inner arch linear and body like no mans business, 10mm spacers were brought and this helped a little bit but not much

so i had decided to get a set of comp mo's with the correct offset which are on order now

.

so as the engine was noisy i decided to get a new engine built.. but a proper spec built.. and built good enough that if i wanted more power in the future it would be just a simple turbo change and injector change then a setup.. here i started speaking to mike rainbird.. the spec was decided on a good solid 450-460bhp. harvey gibbs is currently building my engine

as i was having all this power i knew the standard box and diff wouldn't cope as the box has problems now.. i was considering going down the tremec route but wanted a direct fit so instead i went for a quaife big tooth gearbox and a quaife atb diff