PassionFord - Ford Focus, Escort & RS Forum Discussion

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-   Restorations, Rebuilds & Projects. (https://passionford.com/forum/restorations-rebuilds-and-projects-29/)
-   -   1992 4x4 Sapphire Cosworth Build (https://passionford.com/forum/restorations-rebuilds-and-projects/372221-1992-4x4-sapphire-cosworth-build.html)

Bloomers 28-12-2010 09:44 AM

looks ace mate, keep up the good work

Big_Mike 28-12-2010 11:14 AM


Originally Posted by Glenn. (Post 5258097)
Top work mate its looking good.

Thanks Glen :grin:


Originally Posted by Bloomers (Post 5258569)
looks ace mate, keep up the good work

Thanks Bloomers, hopefully the underside will be as mint as yours soon :grin:

Big_Mike 30-12-2010 01:11 PM

Little Update.


Bored of christmas already! So did some more work on saff. Put all of the carbon bits on :grin: And in doing so had to take the door cards of, rear ones are mint, but both fronts where the pocket is, the leather has pulled a way. But I have found a set for a very reasonable price thanks to Jimbo and Harvey. which will be going on shortly.

http://i50.photobucket.com/albums/f3...n/IMG_1223.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1224.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1228.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1229.jpg




Put the new rear lights on, and gave the paint work behind a bit of a clean.

http://i50.photobucket.com/albums/f3...n/IMG_1225.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1226.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1227.jpg

Put the rear bumper on for no reason, just got a little excited! And Jim was kind enough to give me some bumper fixings that were missing, so thought i'd put both the bumper and spoiler on.

http://i50.photobucket.com/albums/f3...n/IMG_1231.jpg



The spoiler is being painted as we speak, the black bit needs a little tlc, so I thought i'd mask the white off once cleaned, and paint the black part.

Just about to drop a few things of to be zinc plated :grin:

Still cleaning the tank :cry: and have a header tank and pas tank on the way.

Also read the service book, the shell has done 79,000 miles which is always nice to know.

That's all for now.

Just a quick thanks to Jimbo, as I'm sure most of you know he's a top fella, and always happy to help. I'm sure he's sick of me by now! But He's been a massive help with this project so far :top:

Mikey.

KSA-Cossie 30-12-2010 01:27 PM

Coming along m8.

colarado red 30-12-2010 01:40 PM

Nice work.love old school hocks on a cossie:top:

Gav Diamond 30-12-2010 01:45 PM

Looking good Mike, where did you get the door handles done/from?

Big_Mike 30-12-2010 02:39 PM


Originally Posted by KSA-Cossie (Post 5262642)
Coming along m8.

Thanks bud.


Originally Posted by colarado red (Post 5262663)
Nice work.love old school hocks on a cossie:top:


Thanks, You have great taste also :god:



Originally Posted by Gav Diamond (Post 5262668)
Looking good Mike, where did you get the door handles done/from?

Thanks Gav. hmmm, how much is it worth?!

I'll ask Jim when I see him later, it was from the guy he bought his 500 splitter off. They are genuine ford door handles, with a carbon mould on top. But look the part! If not I've got a guy making me some mirror covers. I can ask him if he'll make you some if you like?

J1mbo 30-12-2010 02:45 PM

top work mate :top: carbon looks lush!

Big_Mike 30-12-2010 03:18 PM


Originally Posted by J1mbo (Post 5262728)
top work mate :top: carbon looks lush!

Thanks Jimbo :top:

Eigdoog 03-01-2011 10:21 AM

Just been though this and it looks really good! You defo doing a better job than me :bomb:

Big_Mike 03-01-2011 11:44 AM


Originally Posted by Eigdoog (Post 5269713)
Just been though this and it looks really good! You defo doing a better job than me :bomb:

Hmmmm, not sure about that!! I'm new to all this, and only 21!!! :cry: But thanks. Nice to know that someone else is doing a similar project!! Keep up the good work :top:

Brettski mk2 03-01-2011 06:02 PM

Hi mate
could I ask where I could get my hands on some carbon door handles
Cheers Brett

cameron2 03-01-2011 06:32 PM

Looks spot on mate.

Big_Mike 15-01-2011 03:00 PM


Originally Posted by Brettski mk2 (Post 5270755)
Hi mate
could I ask where I could get my hands on some carbon door handles
Cheers Brett

Not sure, a friend of mine organised them for me, will try and find out.


Originally Posted by cameron2 (Post 5270848)
Looks spot on mate.

Thanks Cameron

RSRoy 15-01-2011 03:08 PM

Nice project you got there. What are the plans on the engine?

Big_Mike 15-01-2011 03:34 PM

Right, little update. things are a little slow at the moment, due to my car insurance going out this month. Would rather of spent the £700 on my engine :cry:

Just doing little buffty bits at the moment. As it needs doing, and is free :grin:

The car is 18 years old, and fairly good nick, but needs a bit of TLC.

The header tank, and pas tank arrived. The header tank isn't the best condition in the world, as the water seems to have been sat at the same level for a long time and stained the plastic, but I wasn't too fussed as this is just there for when I get an alloy one, either before or after the car is running. I tried cleaning it with virtually everything, and wouldn't come up.





http://i50.photobucket.com/albums/f3...n/IMG_1234.jpg




However, the PAS tank didn't come up too bad. I only paid £15 for the header tank, and £12 for the PAS tank. So they will do for now.




http://i50.photobucket.com/albums/f3...n/IMG_1235.jpg




As I work for a sign company, I had some old vinyl laying around, so made a sun strip, to go with the theme of the car.





http://i50.photobucket.com/albums/f3...n/IMG_1239.jpg




As mentioned, the car is in fairly good nick, just needs a dam good clean. So out came the petrol again :top: Took the heater matrix off, and cleaned behind there, and came up pretty well.




http://i50.photobucket.com/albums/f3...n/IMG_1253.jpg





I'm trying to clean everything up, apart from the underside. It's a job i'm really not looking forward to, and at the moment, haven't really got the facilities until I take the front end out, put it on axle stands, paint the arches, suspension and some how get some brackets made for the brembos when they arrive. So I cleaned up to the gearbox tunnel.



Put some paint on the front of the chassis just to tart it up a bit, I know it's not going to be seen once the bumper is on, but I wanna do everything right on this car. So picked up some diamond white. Lacquer will be going on tomorrow.




http://i50.photobucket.com/albums/f3...n/IMG_1254.jpg





Took the seals off around the doors to clean them up a bit. As they has a little rust on them, and also the boot seal. Nothing major, so decided to clean them up. So out came the petrol again. Pics will follow, but as you can see few bits of dirt and rust.


http://i50.photobucket.com/albums/f3...n/IMG_1255.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1257.jpg

http://i50.photobucket.com/albums/f3...n/IMG_1258.jpg


http://i50.photobucket.com/albums/f3...n/IMG_1260.jpg








I've decided for the moment, I don't want a stereo/radio unless I can get hold of a genuine one, as all I want to do is listen to the chatter from the turbo :top: Who wants to listen to a radio in a cossie?!!


So I'm gonna put a few gauges in it's place. Rather than cutting up the air vents. As there aren't many cossies that don't have a boost gauge in the air vent. So the option is always there to put a stereo back in also. So got a piece of mdf, just as a mock up to make the final thing. I've got a plastic frame that came with the kenwood cd player, so will use that off to neaten up the edge. I think a couple of stack gauges will look nice in there :grin:





http://i50.photobucket.com/albums/f3...n/IMG_1264.jpg




Rear door cards are back on after fitting the carbon door handles. Just got to pick my new front ones up, and then they will go on.





http://i50.photobucket.com/albums/f3...n/IMG_1266.jpg



http://i50.photobucket.com/albums/f3...n/IMG_1269.jpg

Will be doing some more work on it tomorrow, and need to sort out the steering rack, as it has a few bolts missing :cry: So will upload some more pics tomorrow.

thanks for reading, Mikey.

Big_Mike 15-01-2011 03:40 PM


Originally Posted by RSRoy (Post 5292391)
Nice project you got there. What are the plans on the engine?

Thank you :top: Nothing the world hasn't seen before. I'm in two minds weather to convert to 2wd, as transmission is gonna be expensive with 4x4 once you get over 400bhp.

So at the moment the plans are, 4x4, t34, light blues etc. Maybe a ported head and cams to see me near 400bhp. I don't want anything to laggy, so will probably be a .48 housing rather than .63

I've read so many good things about this set up, so seems a bit of a no brainer, and a fairly cheap option.

We shall see!!

RSRoy 15-01-2011 03:49 PM


Originally Posted by Big_Mike (Post 5292467)
Thank you :top: Nothing the world hasn't seen before. I'm in two minds weather to convert to 2wd, as transmission is gonna be expensive with 4x4 once you get over 400bhp.

So at the moment the plans are, 4x4, t34, light blues etc. Maybe a ported head and cams to see me near 400bhp. I don't want anything to laggy, so will probably be a .48 housing rather than .63

I've read so many good things about this set up, so seems a bit of a no brainer, and a fairly cheap option.

We shall see!!

Have a bit of same idea for my car, just a nice stage 3 setup would be fine. You gonna do it yourself or do let Jimbo do all the work? :p

Big_Mike 15-01-2011 03:55 PM


Originally Posted by RSRoy (Post 5292490)
Have a bit of same idea for my car, just a nice stage 3 setup would be fine. You gonna do it yourself or do let Jimbo do all the work? :p

That sounds like a good plan. Haha, most things will be done by me, but the engine work will be left to Jimbo and Harvey. I will be helping of course, but I don't know a lot! All a learning curve!

J1mbo 15-01-2011 04:34 PM

Looking good old boy

Dunno whats up with phone, give us a bell again.

RSRoy 15-01-2011 05:22 PM


Originally Posted by Big_Mike (Post 5292496)
That sounds like a good plan. Haha, most things will be done by me, but the engine work will be left to Jimbo and Harvey. I will be helping of course, but I don't know a lot! All a learning curve!

Can't wait for the engine build to start, good luck mate!

bad boy rs 15-01-2011 05:26 PM

put the tanks in the dish washer or block bottom pipes off and leave bleach in the will come up a treat

Big_Mike 15-01-2011 05:56 PM


Originally Posted by RSRoy (Post 5292707)
Can't wait for the engine build to start, good luck mate!

Me neither!! Cheers, let me know how you get on with yours :top:


Originally Posted by bad boy rs (Post 5292715)
put the tanks in the dish washer or block bottom pipes off and leave bleach in the will come up a treat

Cheers fella, didn't want to try it in the dishwasher, as i don't think my Mum would appreciate it :cry:

I might just have to try the bleach though!!

RSRoy 16-01-2011 09:32 AM


Originally Posted by Big_Mike (Post 5292807)
Me neither!! Cheers, let me know how you get on with yours :top:

That will take a while....:cry:


Got some other thing to sort out for this year, exhaust, koni's, bushes, door mouldings, rust. I will update my resto thread when I start on the car again.

Cossy Mike 16-01-2011 12:00 PM


Originally Posted by Big_Mike (Post 5292807)
I might just have to try the bleach though!!

Bleach works a treat, put some rice in it as well, then slosh it around, the rice will clean in better :thumbup:

jason_nike 16-01-2011 02:13 PM

Looking good, plenty of work to keep you busy tho

Big_Mike 16-01-2011 06:30 PM


Originally Posted by RSRoy (Post 5293728)
That will take a while....:cry:


Got some other thing to sort out for this year, exhaust, koni's, bushes, door mouldings, rust. I will update my resto thread when I start on the car again.

Sounds like your gonna be busy!!! Will keep my eye on the thread :top:


Originally Posted by saphcosmike (Post 5293935)
Bleach works a treat, put some rice in it as well, then slosh it around, the rice will clean in better :thumbup:

Would never of thought of that. I will certainly try! Thanks bud :top:


Originally Posted by jason_nike (Post 5294114)
Looking good, plenty of work to keep you busy tho

Yep!! Keeps me out of trouble though!! :cry:

Big_Mike 16-01-2011 06:43 PM

Little update, didn't work on the car itself though. A hangover got the better of me!

However, went on a scrounge! Popped to SCS, to collect some bits of a written off saph.

Finally cleaned the petrol tank up, so this will be sent off for powder coating now, and have various bolts of things to be zinc plated. Really chuffed how the tank came out.



http://i50.photobucket.com/albums/f3...n/IMG_1279.jpg


Picked up, some screws for the header tank, brackets for the heat shield, bracket for the map sensor, cleaner bulkhead cover, header tank cap, brackets for the grill that connects to the lights, various screws, fuel pump and cradle, rubber seals, and loads more.



http://i50.photobucket.com/albums/f3...n/IMG_1277.jpg


http://i50.photobucket.com/albums/f3...n/IMG_1278.jpg


http://i50.photobucket.com/albums/f3...n/IMG_1281.jpg


Finished painting the fog surrounds, so next job is making the air ducts!


http://i50.photobucket.com/albums/f3...n/IMG_1280.jpg


Not an exciting update, but now have a lot of cleaning to do!!!
Thanks for reading.

Mikey.

Cossy Mike 16-01-2011 07:11 PM

Have a look inside of your petrol tank, it looks like a genuine Ford one to me and it will have a plastic swirl pot in it.

If it is you'll not be able to get it coated as it will just melt with the heat!

Double check just to make sure...

J1mbo 16-01-2011 07:14 PM

I had mine done and its fine so has another mate all by the same coater and he knows about the plastic bit too!?

Big_Mike 23-01-2011 10:35 AM


Originally Posted by saphcosmike (Post 5295005)
Have a look inside of your petrol tank, it looks like a genuine Ford one to me and it will have a plastic swirl pot in it.

If it is you'll not be able to get it coated as it will just melt with the heat!

Double check just to make sure...

Thanks mate. Jimbo's had one done before, and was fine. So gonna give it a try!

Big_Mike 23-01-2011 10:37 AM

Little update.....


Work has taken over my life as usual, and it's not even summer yet!!

So not much work has been done, however, my Brembos turned up :grin:

Thanks to Kelv and Jimbo on this one! Will get pics up soon.

Cossy Mike 23-01-2011 12:04 PM


Originally Posted by Big_Mike (Post 5305272)
Thanks mate. Jimbo's had one done before, and was fine. So gonna give it a try!

Lot of money to risk it.....

The tank I put in had metal inners with the only plastic item being a plastic clip on gauze on the fuel pick up pipe and evan that was destroyed, it was a hard goey mess.

I simply fabricated a new one....

best of luck :thumbup:

Big_Mike 23-01-2011 12:24 PM


Originally Posted by saphcosmike (Post 5305378)
Lot of money to risk it.....

The tank I put in had metal inners with the only plastic item being a plastic clip on gauze on the fuel pick up pipe and evan that was destroyed, it was a hard goey mess.

I simply fabricated a new one....

best of luck :thumbup:

Your making me nervous about it now! Might leave it, looks clean enough!

Eigdoog 23-01-2011 09:34 PM


Originally Posted by Big_Mike (Post 5269860)
Hmmmm, not sure about that!! I'm new to all this, and only 21!!! :cry: But thanks. Nice to know that someone else is doing a similar project!! Keep up the good work :top:

Im only 21 and you defo have done a better job lol. I know mines similar but yours is way better:top:

How much is your insurance? Best i got was £1500 ish then after that i got £4000+

GOOD JOB!!:king:

Big_Mike 25-01-2011 09:51 PM


Originally Posted by Eigdoog (Post 5306780)
Im only 21 and you defo have done a better job lol. I know mines similar but yours is way better:top:

How much is your insurance? Best i got was £1500 ish then after that i got £4000+

GOOD JOB!!:king:


Ha, I have no idea what i'm doing :cry:

Lowest i've got is £2200, so got my Pop to insure it for now :top: Not gonna have it on the road for a while yet, so didn't see the point in getting it insured for me!

Where about's are you in cambridgeshire? Can't be too far from me!

£1500 is cheap as!!

How's the project coming along?

Big_Mike 25-01-2011 09:53 PM

Sorry for the terrible picture!

But here is the brembos.

324 4 pots. Should look nice under the 17's!

http://i50.photobucket.com/albums/f3..._3466936_n.jpg

Front end is being stripped out this weekend and put on axle stands.

More updates soon.

Thanks for reading.

Big_Mike 30-01-2011 04:37 PM

Little update, stripped the front suspension and engine cradle today...

http://i50.photobucket.com/albums/f3...n/IMG_1310.jpg




http://i50.photobucket.com/albums/f3...n/IMG_1311.jpg



http://i50.photobucket.com/albums/f3...n/IMG_1312.jpg



Then managed to clean up one of the arches, and primed it. Hopefully I'll be sending some powder coating and plating off, along with the engine cradle.



http://i50.photobucket.com/albums/f3...n/IMG_1317.jpg




Not sure weather to re spray the koni's or put some gaz collies on ???

Have got some better pics of the brakes also.... And wanted to see what they looked like under the wheels.


http://i50.photobucket.com/albums/f3...n/IMG_1316.jpg




http://i50.photobucket.com/albums/f3...n/IMG_1313.jpg



Things are slow with progress at the moment, but hopefully i'll get my act together and send the stuff of for plating and powder coating, then I can start putting things back together!

Thanks for reading.

bad boy rs 30-01-2011 04:44 PM

looking good mate them brakes work well used to have that setup

RSRoy 30-01-2011 06:39 PM

Go for Koni's with Ahmed springs Mike. You can get the springs form Mike Rainbird.


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