Sierra cosworth 24v turbo! home built and mapped
04-08-2010, 12:09 PM
#1
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
Sierra cosworth 24v turbo! home built and mapped
Hi, and welcome to my first project thread!, i have done several homebrew turbo projects before, all running megasquirt, all built and mapped by me, but ive been out of touch for the past year or so due to buying a house and moving etc. So when the chance came i decided to buy a sierra sapphire, as ive always fanncied one, Not wanting to buy a cosworth as A, they are too dear and B, i wanted to build my own project, to be a little different. Plus the fun for me is in the build, using your imagination as to what different bits i can use for the project from various other manufacturers etc.
This project is never going to be concours or the fastest thing in the world, but it will not cost the earth and i will certainly enjoy building it! So please enjoy my thread for what it is and not how much it cost. I will try to do all the work myself (painting, mechanics, welding etc) but if i enlist the help of a mate i will happily mention them.
So the plan is as follows... Sierra sapphire 1.8 glx, going to be converted to v6 cosworth turbo, rwd, cosworth rear running gear, megasquirt efi engine management, bodywork restoration, including full respray in mallrd green (anyone ever seen a mallard saff?). Looking for around 300 bhp, at about 7psi of boost, safe as houses and reliable and very torquey on and off boost.
This project is never going to be concours or the fastest thing in the world, but it will not cost the earth and i will certainly enjoy building it! So please enjoy my thread for what it is and not how much it cost. I will try to do all the work myself (painting, mechanics, welding etc) but if i enlist the help of a mate i will happily mention them.
So the plan is as follows... Sierra sapphire 1.8 glx, going to be converted to v6 cosworth turbo, rwd, cosworth rear running gear, megasquirt efi engine management, bodywork restoration, including full respray in mallrd green (anyone ever seen a mallard saff?). Looking for around 300 bhp, at about 7psi of boost, safe as houses and reliable and very torquey on and off boost.
Last edited by chaffe; 05-10-2010 at 07:55 AM.
06-08-2010, 06:50 AM
#5
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
Polished any dust out last night, car is looking good. next plan is to start on the doors and bonnet etc, i will try and post some pics up soon. Glad i went for mallard, really like the way it changes colour in different lights.
Trending Topics
[/IMG]
10-08-2010, 05:18 AM
#16
Get to tha choppa!
Join Date: Jul 2009
Location: West Mids
Posts: 411
Likes: 0
Received 0 Likes
on
0 Posts
Wow! That paint job looks pretty high quality for a in-house jobbie. I cannot see any sort of dirt particles where the light hits it.
Had it already been wet sanded in those pictures?
Had it already been wet sanded in those pictures?
10-08-2010, 06:07 AM
#17
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
thanks, and yeah i chose to take the pics after i polished it lol, i went round the garage with the hose pipe before i painted it mind 
10-08-2010, 11:30 AM
#21
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
13-08-2010, 11:37 AM
#23
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
Just a quick update, i have some space again in my garage after repairing a mates car. So i am in the process of repairing and priming the doors and other pannels, hope to have it all primed and rubbed down by the end of the weekend. Then i can paint a couple of items every couple of days and fit and polish them as i go. I will update the thread with pictures as i go.
Then i can start on the installation of my engine, the engine management, and turbocharger. im am using the excisting manifolds and collecting them using custom pipes made by myself, i will also have to provise a downpipe and oil feed and return, nothing too taxing but ity will require a bit of thought.
Then i can start on the installation of my engine, the engine management, and turbocharger. im am using the excisting manifolds and collecting them using custom pipes made by myself, i will also have to provise a downpipe and oil feed and return, nothing too taxing but ity will require a bit of thought.
23-08-2010, 07:38 PM
#27
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
a few more pics of the car comming together, painted the other two doors earlier, will be fitting them this week.
24-08-2010, 06:54 AM
#29
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
25-08-2010, 06:20 PM
#34
Turbocharging Technician
Thread Starter
Join Date: Jul 2010
Location: Top secret. Mission:Imposible.
Posts: 3,557
Likes: 0
Received 0 Likes
on
0 Posts
Fitted the two drivers doors last night and put the bonnet on temporary to check fit. also gave the car a good flat and polish with the machine polisher to take out some paint texture and bring up the shine to a higher standard. next plan is to paint the roof as this has been left out due to the car being soo close to the roof when it was painted, i also wanted to do it seperatly to keep the dust and nibs to a minimum by doing it on its own. anyway some more pics 
