1986 Sierra Cosworth Moonstone Restoration
24-08-2009, 10:35 PM
#43
Shizzle My Nizzle
Thread Starter
iTrader: (1)
Join Date: Aug 2006
Location: ESSEX
Posts: 3,755
Likes: 0
Received 0 Likes
on
0 Posts
Right finally managed to find a few hours, wanted to have it all out, but ran out of time.
Only struts and gearstick/interior center console to undo, but am waiting untill tommrow, Prob better as I wont be greasy and oily then either!
grille off
These have become an essential item when having to open the doors or boot to gain access to nuts/bolts etc
The FFing
Clifford alarm has a mind of its own. The button on the remote does not always work? Im guessing the battery must be getting flat?
Lights out
This car is in supprisingly good condition for a 23 year old ford, only a very small showing of rust and its mostly surface.
This looks like the seam sealer has simply shrunk and let water to ingerss. Very easy to repair tho.
Bumper - Why ford made them stupid baynot fittingsout of plastic I dont know. A good quick design but so bloody flimsy. 3 - I managed to get out ok and are in good condition but one was badly mangled to start with, as the bumper has definalty been off before. So if anyone has one for sale then give me a shout please.
Ignore this pic, its just a reference picture for me if i need it.
Header, washer, power pump res all shifted and all looms and connections disconnected and FULLY LABELED All nuts and bolts are also labeled, may seem ott and time consuming, but its actually a time saving attribute as everything goes back how it should and in the correct place.
Good job Im on the case with a resto, a lot of rubber components are at the end of their life. Will be intresting to see the cam belt when the cover is off. just check out the PAS belt, just in time this one!
All a bit grubby, there apperas to be an oil leak from some where, to early to say what it is yet but it look like its been there for a while, my guess is leaking rocker cover gasket.
Rear bumper off - very impressed with it under here no signs of rot, not even surface rust anywhere.
Couple off the dirty underside and diff
The front tyres are worn and are boarder line legal, they wont pass another MOT anyway. a fair bit of wear on inner edge, due to negative camber im guessing. Will see if this is better after the new bushes are fitted and its all tight again.
inner
outer
Front disks are drilled items and are in great shape with very little wear, the insides have glazed up a bit and the holes are blocked with break dust. but nothing a good clean cant sort
Couple of under side shots
Couple of the oil leak close up
Front cross members are solid, with only surface rust on seam joins.
HAHAHA
Clifford alarm 0 - Lee 1
Managed to trick the alarm with some jumpleads
Well not a bad effort, really wanted the engine out tonight, but its best not to rush these things. Its all ready, just anti rool bar and engine mounts to unbolt and remove center console to disconect gearstick and shes out.
Only struts and gearstick/interior center console to undo, but am waiting untill tommrow, Prob better as I wont be greasy and oily then either!
grille off
These have become an essential item when having to open the doors or boot to gain access to nuts/bolts etc
The FFing
Clifford alarm has a mind of its own. The button on the remote does not always work? Im guessing the battery must be getting flat?Lights out
This car is in supprisingly good condition for a 23 year old ford, only a very small showing of rust and its mostly surface.
This looks like the seam sealer has simply shrunk and let water to ingerss. Very easy to repair tho.
Bumper - Why ford made them stupid baynot fittingsout of plastic I dont know. A good quick design but so bloody flimsy. 3 - I managed to get out ok and are in good condition but one was badly mangled to start with, as the bumper has definalty been off before. So if anyone has one for sale then give me a shout please.
Ignore this pic, its just a reference picture for me if i need it.
Header, washer, power pump res all shifted and all looms and connections disconnected and FULLY LABELED
All nuts and bolts are also labeled, may seem ott and time consuming, but its actually a time saving attribute as everything goes back how it should and in the correct place.Good job Im on the case with a resto, a lot of rubber components are at the end of their life. Will be intresting to see the cam belt when the cover is off. just check out the PAS belt, just in time this one!
All a bit grubby, there apperas to be an oil leak from some where, to early to say what it is yet but it look like its been there for a while, my guess is leaking rocker cover gasket.
Rear bumper off - very impressed with it under here no signs of rot, not even surface rust anywhere.
Couple off the dirty underside and diff
The front tyres are worn and are boarder line legal, they wont pass another MOT anyway. a fair bit of wear on inner edge, due to negative camber im guessing. Will see if this is better after the new bushes are fitted and its all tight again.
inner
outer
Front disks are drilled items and are in great shape with very little wear, the insides have glazed up a bit and the holes are blocked with break dust. but nothing a good clean cant sort
Couple of under side shots
Couple of the oil leak close up
Front cross members are solid, with only surface rust on seam joins.
HAHAHA
Clifford alarm 0 - Lee 1
Managed to trick the alarm with some jumpleads
Well not a bad effort, really wanted the engine out tonight, but its best not to rush these things. Its all ready, just anti rool bar and engine mounts to unbolt and remove center console to disconect gearstick and shes out.
25-08-2009, 07:32 AM
#47
Shizzle My Nizzle
Thread Starter
iTrader: (1)
Join Date: Aug 2006
Location: ESSEX
Posts: 3,755
Likes: 0
Received 0 Likes
on
0 Posts
This one I can do with my eyes closed, Its running, taxed and mot'd, just how I like them.
If its all there to start with, and working. The hardest part is simple labeling everything up. Everything else is just nuts and bolts
I always buy cars which are majorly incomplete, (my S1RST springs to mind
) which is half the problem. The Rsi was a nightmare, bought as a bare rolling shell and as id never worked on one before so didnt know much about them as the engines are totally unique to the rsi. that coupled with buying sub grade second hand parts anf faulty parts, but I guess thats the risk you take buying second hand.
Anyway Really enjoying this project and thats the way it should be, of course there will be swearing and cursing, but It got to the point with the rsi where I couldnt even bare to look at it.
More updates tonight
If its all there to start with, and working. The hardest part is simple labeling everything up. Everything else is just nuts and bolts
I always buy cars which are majorly incomplete, (my S1RST springs to mind
) which is half the problem. The Rsi was a nightmare, bought as a bare rolling shell and as id never worked on one before so didnt know much about them as the engines are totally unique to the rsi. that coupled with buying sub grade second hand parts anf faulty parts, but I guess thats the risk you take buying second hand.Anyway Really enjoying this project and thats the way it should be, of course there will be swearing and cursing, but It got to the point with the rsi where I couldnt even bare to look at it.
More updates tonight
Last edited by Lee Ivatt; 25-08-2009 at 11:43 AM.
25-08-2009, 06:58 PM
#50
Shizzle My Nizzle
Thread Starter
iTrader: (1)
Join Date: Aug 2006
Location: ESSEX
Posts: 3,755
Likes: 0
Received 0 Likes
on
0 Posts
Some more tonight
Little bit of internal fiddeling
Running out of room. my Vw engines in the wood workshop now
Rip down a bit of 4x2 to a smaller 2x2
Mark and cut
Drill
Can you guess what it it yet..........................................
Ive made a jig to move it around easily untill it pull it apart. BUT I just realised I inadvertantly have built the WORLDS FASTEST TRIKE
Doesnt look much like a cossie anymore
Off side front is good but does have a tiny hole around the bulkhead wall which will need cutting out and welding
Nearside front
Is clean no rust here
Exhaust off, its actually a powerflow item. Didnt realise this as its so quite when running. thought it would be louder, looking at the tail pipe. Personally dont like loud exhausts anyway, well not on cossies/rst's.
Rear tyre on closer inspection are also worn, with major wear on inner edge again
This one has caught and ripped the plastic, quite some time ago as is apparant in the next pics
and also has been rubbing at some stage
Just behind it is some rust, this is the worst bit on the whole car.
Its around the rear suspension and rear chassis leg. Again very impressive for such an old car. My guess is it has only occoured due to the broken plastic cover and water/dirt being thrown into the gap where the spot welds are
Off side rear is much better with only a sprinkle of surface rust
And a small patch where the bumper at some point in the past has rubbed throught the paint
Last job today was to bleed the fueltank. Bloody good I was well prepared, as there was far more in there than I had thought
Little bit of internal fiddeling
Running out of room. my Vw engines in the wood workshop now
Rip down a bit of 4x2 to a smaller 2x2
Mark and cut
Drill
Can you guess what it it yet..........................................
Ive made a jig to move it around easily untill it pull it apart. BUT I just realised I inadvertantly have built the WORLDS FASTEST TRIKE
Doesnt look much like a cossie anymore
Off side front is good but does have a tiny hole around the bulkhead wall which will need cutting out and welding
Nearside front
Is clean no rust here
Exhaust off, its actually a powerflow item. Didnt realise this as its so quite when running. thought it would be louder, looking at the tail pipe. Personally dont like loud exhausts anyway, well not on cossies/rst's.
Rear tyre on closer inspection are also worn, with major wear on inner edge again
This one has caught and ripped the plastic, quite some time ago as is apparant in the next pics
and also has been rubbing at some stage
Just behind it is some rust, this is the worst bit on the whole car.
Its around the rear suspension and rear chassis leg. Again very impressive for such an old car. My guess is it has only occoured due to the broken plastic cover and water/dirt being thrown into the gap where the spot welds are
Off side rear is much better with only a sprinkle of surface rust
And a small patch where the bumper at some point in the past has rubbed throught the paint
Last job today was to bleed the fueltank. Bloody good I was well prepared, as there was far more in there than I had thought
Last edited by Lee Ivatt; 25-08-2009 at 07:02 PM.
25-08-2009, 08:16 PM
#52
PassionFord Post Whore!!
Another one begins its new life of mintyness
26-08-2009, 04:57 AM
#58
Great project mate
As for the bumper twist things, if you do a search on ebay for sierra cosworth bumper there are normally new ones on there.
Only some 2nd hand at the minute http://cgi.ebay.co.uk/SIERRA-COSWORT...d=p3286.c0.m14
As for the bumper twist things, if you do a search on ebay for sierra cosworth bumper there are normally new ones on there.
Only some 2nd hand at the minute http://cgi.ebay.co.uk/SIERRA-COSWORT...d=p3286.c0.m14
26-08-2009, 07:53 AM
#61
Shizzle My Nizzle
Thread Starter
iTrader: (1)
Join Date: Aug 2006
Location: ESSEX
Posts: 3,755
Likes: 0
Received 0 Likes
on
0 Posts
a 5p piece sive on off side inner wing
a 10p size piece on the near side rear chassis leg
a 4" surface bubble on the off side rear 1/4 skin behind the bumper
and 2 areas of surface rust on the front chassis rails/bumper mount, where seam sealer has shrunk
Im not sure but guessing you have NEVER restored a ford mate before.
This car is like a dream come true.
This is probably one of the best and minimum rusted ford out there which is at this monent TOTALLY UNRESTORED AND UNWELDED AND STILL IN 23 YEAR OLD ORIGINAL PAINT!
The Aston Martin had 20 times more rust than this, and 90% of the body is made of alluminum!
ANd as for my Series One, I reckon 40-50% or that car I put new metal in!!!!!!!
Last edited by Lee Ivatt; 26-08-2009 at 07:58 AM.
26-08-2009, 09:02 AM
#63
Too many posts.. I need a life!!
Join Date: May 2004
Location: Mikkeli, Finland
Posts: 844
Likes: 0
Received 0 Likes
on
0 Posts
a 5p piece sive on off side inner wing
a 10p size piece on the near side rear chassis leg
a 4" surface bubble on the off side rear 1/4 skin behind the bumper
and 2 areas of surface rust on the front chassis rails/bumper mount, where seam sealer has shrunk
Im not sure but guessing you have NEVER restored a ford mate before.
This car is like a dream come true.
This is probably one of the best and minimum rusted ford out there which is at this monent TOTALLY UNRESTORED AND UNWELDED AND STILL IN 23 YEAR OLD ORIGINAL PAINT!
The Aston Martin had 20 times more rust than this, and 90% of the body is made of alluminum!
ANd as for my Series One, I reckon 40-50% or that car I put new metal in!!!!!!!
My car was Imported from southern germany where is pretty good climate to old and easy rusting fords
So i mean those aren´t bad, bud suprised me. Is british climate so bad to old cars? Because here in Finland original "Finnish-Fords" are rust buckets too.. thats why i imported car from Germany.
and the rust:
All now naturally fixed. There was also soft under battery tray just a little bit but i decided to fix that too properly.
I have seen here in Finland SO BADLY rosted fords i only wonder why they still drive with those rost buckets.
But lets see how your restoration goes on, i really like your rs1600i project story and pictures and looking forward how this goes
Best Regards
Antti-Ville
Last edited by Antti O; 26-08-2009 at 09:04 AM.
26-08-2009, 06:52 PM
#66
Shizzle My Nizzle
Thread Starter
iTrader: (1)
Join Date: Aug 2006
Location: ESSEX
Posts: 3,755
Likes: 0
Received 0 Likes
on
0 Posts
Dont joke, I estimated 4-6 weeks turn around.
Just a pain in the arse next week I will not be able to touch anything, as im busy with other things which cant be shifted around in the diary
So yeh its gonna be 6 weeks if not 8
which im not happy about as I need to get the beetle finished and I also have my eyes on another project ive known about for the last year and have 1st dibbs on.
More stripping
Body kit off, so pleased with what I found, rusty cills are probably my most hated job, but these are in amazing condition!!
Off side rear
Very small bubble on top of arch, looks like where the body kit has rubbed through the paint over the years
very small bit of rust on leading edge of lower arch, but not a big deal
Off side cill, solid as a rock just grubby from years of grime
Off side front
Some one has mashed one of the body kit fixing holes and then drilled 2 rivets each side of this, so something that will have to be fixed
that rust spot that was hiding behind the arch liner, luckily it was no worse than it first looked, again an easy repair.
Arch liners were such a good idea, why didnt ford introduce these earlier on with the mk3 escorts. Just look how soild it is, all original and rust free
First swearing at the car, both self securing nuts on the tank decided they were not self securing after 23 years
So close to the fuel tank and with very limited room couldnt even get a spanner in the top, so only option was to use a hacksaw blade, took a while
just look how fresh it is above the tank
Fuel pump off, again soooo impressed nuts came off with only a little bit of effore with no broken nuts/studs of anything. Must have been a first for me when it comes to fuel pump brackets. The one on my S1 litterally turned in to powder when I touched it, and they are impossible to buy second hand. So this has to be the highlight of todays efforts!
Near side rear kit off
this arch is ok
Near side front - again perfect no rust
Near side cill also in great shape
Prop
Rear suspension and diff
So pretty much there now, a few looms and fuel/break lines still on, some I may leave on and work around, not sure yet. will see how the condition is when all the waxoil is removed
sorry about this shot the "trike" was in the way
Fast ford are coming round to do a photo shoot tommrow on the RS1600i so advance appologies if material content is lacking tommrow
Just a pain in the arse next week I will not be able to touch anything, as im busy with other things which cant be shifted around in the diary
So yeh its gonna be 6 weeks if not 8
which im not happy about as I need to get the beetle finished and I also have my eyes on another project ive known about for the last year and have 1st dibbs on.More stripping
Body kit off, so pleased with what I found, rusty cills are probably my most hated job, but these are in amazing condition!!
Off side rear
Very small bubble on top of arch, looks like where the body kit has rubbed through the paint over the years
very small bit of rust on leading edge of lower arch, but not a big deal
Off side cill, solid as a rock just grubby from years of grime
Off side front
Some one has mashed one of the body kit fixing holes and then drilled 2 rivets each side of this, so something that will have to be fixed
that rust spot that was hiding behind the arch liner, luckily it was no worse than it first looked, again an easy repair.
Arch liners were such a good idea, why didnt ford introduce these earlier on with the mk3 escorts
. Just look how soild it is, all original and rust freeFirst swearing
at the car, both self securing nuts on the tank decided they were not self securing after 23 years So close to the fuel tank and with very limited room couldnt even get a spanner in the top, so only option was to use a hacksaw blade, took a while
just look how fresh it is above the tank
Fuel pump off, again soooo impressed nuts came off with only a little bit of effore with no broken nuts/studs of anything. Must have been a first for me when it comes to fuel pump brackets. The one on my S1 litterally turned in to powder when I touched it, and they are impossible to buy second hand. So this has to be the highlight of todays efforts!
Near side rear kit off
this arch is ok
Near side front - again perfect no rust
Near side cill also in great shape
Prop
Rear suspension and diff
So pretty much there now, a few looms and fuel/break lines still on, some I may leave on and work around, not sure yet. will see how the condition is when all the waxoil is removed
sorry about this shot the "trike" was in the way
Fast ford are coming round to do a photo shoot tommrow on the RS1600i so advance appologies if material content is lacking tommrow
26-08-2009, 07:08 PM
#67
Team HOTHOT!
Impressive stuff Lee - And I wasn't joking on the time scale - seems that you and me are similar in the fact that once we get a project on the go, we have to crack on regardless and quickly - Take the E30 Cosworth I did, 3 months from start to finish with nothing but a shell and a massive pile of bits. Then the latest Cosworth of mine - 5 weeks from start to finish (bar those silly things you find once you start to drive it) - that again was a total stripdown and rebuild of pretty much everything bar the power plant
31-08-2009, 08:24 AM
#76
Enthusiast
Join Date: Dec 2004
Location: Colchester, Essex
Posts: 138
Likes: 0
Received 0 Likes
on
0 Posts
15k for a start
Most people these days think is just a chaved up escort or 1.3 replica (I think everytime i pulled in to get fuel [which was very often] someone would ask "is that a real one?" of course id say NO just to be safe)
Rediculus insurance
Cant leave it or park it anywhere
Every cnut under the sun wants a race
Not to mention the notorious "cossie paranoia"
And basically a lot of money for not a lot of car.
Ever since I first saw one drive past when they were new back in about 1993 I was at school in the playground.
I only knew what it was due to seeing them rallying on TV, but knew I wanted one. Some weird reason I had a disposable camera with me and managed to get a pic of it through the school railings. Will try and find the pic.
15 Years later Dream was realised. And as my sig says........
When all of your wishes are granted many of your dreams will be destroyed
I guess also if im honest, I didnt have enough disiplin and some times would drive like a cock. I dont mean like a BMW M3 driver (), but on the twistys Id be in colin mcrae mode, such such fun but dangerous and selfish, would have only ended in tears eventually. That sort of power is addictive.
And I suppose due to having high quality "every" day cars the last few years, ive kind of spoilt my self as well.
Anyway my next car which is also a childhood dream is on the horizon, once all these others are done. Im not going to say what it is and I am almost willing to bet £100 no one will know what it is, but when they see it, it will be like automotive porn 
(well once ive built it)
Most people these days think is just a chaved up escort or 1.3 replica (I think everytime i pulled in to get fuel [which was very often] someone would ask "is that a real one?" of course id say NO just to be safe)
Rediculus insurance
Cant leave it or park it anywhere
Every cnut under the sun wants a race
Not to mention the notorious "cossie paranoia"
And basically a lot of money for not a lot of car.
Ever since I first saw one drive past when they were new back in about 1993 I was at school in the playground.
I only knew what it was due to seeing them rallying on TV, but knew I wanted one. Some weird reason I had a disposable camera with me and managed to get a pic of it through the school railings. Will try and find the pic.
15 Years later Dream was realised. And as my sig says........
When all of your wishes are granted many of your dreams will be destroyed
I guess also if im honest, I didnt have enough disiplin and some times would drive like a cock. I dont mean like a BMW M3 driver (
), but on the twistys Id be in colin mcrae mode, such such fun but dangerous and selfish, would have only ended in tears eventually. That sort of power is addictive.And I suppose due to having high quality "every" day cars the last few years, ive kind of spoilt my self as well.
Anyway my next car which is also a childhood dream is on the horizon, once all these others are done
. Im not going to say what it is and I am almost willing to bet £100 no one will know what it is, but when they see it, it will be like automotive porn (well once ive built it) My childhood fantasy car is an Escort Cosworth. Same as you i have admired them since a child and only drve one for the first time a month ago and im now 27. It was a standard, dirty, slow old Escort, but i didnt care. I have to have to one and im going to damn well make sure i do. Even if it lives in the unit with my other cars just for me to look at, im gonna have one!
I so hope i dont end up disliking it!
