Dutch Ford Sierra RS Cosworth 4wd BIG rebuild 500+ bhp
31-08-2012, 04:03 PM
#82
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
this weekend another update did alot since the last one, everything is nearly finished for fireing up the car for the first time, maybe next weekend..
14-11-2012, 08:16 PM
#84
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
okay more then 2 months went by, alot happened.
Tried to fire up the car a while ago, but not even a sound that the engine wants to run while cranking.
To keep it short, it had no compression at all at all 4 cylinders
Everything was fitted right and couldn't see another option taking the head off again
So I did that and I discovered that the inletvalves stayed open very little (0,10mm) while they should be closed. Camshaft profile was OK and it turned out that the valves seats were laying waay deeper into the head then a standard 4wd head which I have laying on the shelf.
The wankers from the Dutch HB Motorsport ruined this part of head causing that the hydraulic tappets were totally pressed in and keeping the valves open.
Easiest solution was a camshaft with a smaller base diameter so this was ordered by Mark Shead from MADevelopments who is also going to map the car on the ViPec.
Camshaft came in today and this should solve the problem so going to build everything back this weekend and then turn the key
In this 2 months time I also lost some motivation so I took a few weeks off the project but now want to work on it again.
More upcoming weekend
A little empty
All the parts that need to go on this weekend again
Little close up of the cars wiring loom completely re-done by myself
Tried to fire up the car a while ago, but not even a sound that the engine wants to run while cranking.
To keep it short, it had no compression at all at all 4 cylinders
Everything was fitted right and couldn't see another option taking the head off again
So I did that and I discovered that the inletvalves stayed open very little (0,10mm) while they should be closed. Camshaft profile was OK and it turned out that the valves seats were laying waay deeper into the head then a standard 4wd head which I have laying on the shelf.
The wankers from the Dutch HB Motorsport ruined this part of head causing that the hydraulic tappets were totally pressed in and keeping the valves open.
Easiest solution was a camshaft with a smaller base diameter so this was ordered by Mark Shead from MADevelopments who is also going to map the car on the ViPec.
Camshaft came in today and this should solve the problem so going to build everything back this weekend and then turn the key
In this 2 months time I also lost some motivation so I took a few weeks off the project but now want to work on it again.
More upcoming weekend
A little empty
All the parts that need to go on this weekend again
Little close up of the cars wiring loom completely re-done by myself
15-11-2012, 06:54 AM
#85
I've found that life I needed.. It's HERE!!
Join Date: Mar 2007
Location: The Netherlands
Posts: 1,057
Likes: 0
Received 0 Likes
on
0 Posts
What an idiots there at HB Motorsport 
I'll never use a so called Dutch Cosworth specialist in the future...
Good luck with the rest of the project Stephan, really looking forward to see it completed. Guess you will bring it to a Ford event next year?
I'll never use a so called Dutch Cosworth specialist in the future...
Good luck with the rest of the project Stephan, really looking forward to see it completed. Guess you will bring it to a Ford event next year?
18-11-2012, 09:33 PM
#88
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
as planned started rebuilding everything after the problem this weekend. some pics;
Tighting crankshaft pulley with tool.
Pulled out one of the cam cap studs thread in the head while torquing up the nuts to the right Nm / lbs ft So this is were I needed to stop for this weekend.
Going to fix this by stepping up to new M9 thread instead of the original M8 thread. Need to make some tools at my work so I can properly drill and tap a new thread into the head. Needs to be straight ofcourse and want to do it good. Also need to make a new M9 stud but this is no problem at work.
New updates will be by the end of upcoming week I think.
Beside all this I've also got some documentation from a local Ford dealer. It's all real Dutch and original documentation almost untouched
And also some Cosworth 4wd microfiches in Dutch. Would like to know what's on there is says Service Fiche for Escort / Sierra Cosworth NL
Tighting crankshaft pulley with tool.
Pulled out one of the cam cap studs thread in the head while torquing up the nuts to the right Nm / lbs ft
So this is were I needed to stop for this weekend.Going to fix this by stepping up to new M9 thread instead of the original M8 thread. Need to make some tools at my work so I can properly drill and tap a new thread into the head. Needs to be straight ofcourse and want to do it good. Also need to make a new M9 stud but this is no problem at work.
New updates will be by the end of upcoming week I think.
Beside all this I've also got some documentation from a local Ford dealer. It's all real Dutch and original documentation almost untouched
And also some Cosworth 4wd microfiches in Dutch. Would like to know what's on there is says Service Fiche for Escort / Sierra Cosworth NL
18-11-2012, 09:48 PM
#89
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
HB Motorsport is just a bad company, it is in the top 5 of biggest mistakes in my life letting them do their thing to my engine/head.
It is just 1 person working there and he may know his stuff but he does it all wrong (dutch word, beunhaas) and almost no customer friendly after you've paid
He says he can get/made every part / modification for your car but in the end he just buys it from the UK and adding alot of profit when he sells it to you. Better get your parts from the UK yourself.
But I'll try to do these things better with the other car
It is hard working doing 2 cars but this one is almost ready and my dad is helping me with the next one.
the end is in sight
23-11-2012, 04:22 PM
#95
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
Tonight I'll be preparing some things for this weekend like fixing the thread from the cam cap stud I really can't see any problem to fire up the car Saturday evening or Sunday. Really looking forward to it and hoping that it starts this time
24-11-2012, 09:43 PM
#97
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
done alot this week preparing and worked on the car today.. Ready to start the car tommorow..
Machining some 'jigs' so I could drill / tap straight in the head you can't drill 100% straight by hand
Mounted the drilling jig onto the head
After drilling I did put the special helicoil tap into the tapping jig so I can tap straight into the head
In progress
Straight
Nice special thread ready for helicoil. Forgot to take picture of that
Cams in
Timing belt on
Other parts on
Cam cover gaskets
Making oil pressure by driving the oil pump with drilling machine
Oil coming out of the turbo oilfeed hose, good sign
How it was this afternoon.. I did put the exhaust on it this evening and some small stuff.
Only need to put the battery in, working trough my checklist to check everything i installed and then see if the car wants to come alove.. Really looking forward to it.
Fun thing, exactly 2 years ago in the same weekend 2010 I picked up the car and drove it home
Machining some 'jigs' so I could drill / tap straight in the head you can't drill 100% straight by hand
Mounted the drilling jig onto the head
After drilling I did put the special helicoil tap into the tapping jig so I can tap straight into the head
In progress
Straight
Nice special thread ready for helicoil. Forgot to take picture of that
Cams in
Timing belt on
Other parts on
Cam cover gaskets
Making oil pressure by driving the oil pump with drilling machine
Oil coming out of the turbo oilfeed hose, good sign
How it was this afternoon.. I did put the exhaust on it this evening and some small stuff.
Only need to put the battery in, working trough my checklist to check everything i installed and then see if the car wants to come alove.. Really looking forward to it.
Fun thing, exactly 2 years ago in the same weekend 2010 I picked up the car and drove it home
24-11-2012, 09:53 PM
#98
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
Never ever drive it in the rain and it won't rust and stay in this condition with you as owner
25-11-2012, 04:51 PM
#102
Advanced PassionFord User
Thanks for the great comments, Glad you like the old girl!
Look forward to more of your updates
Tarren
26-11-2012, 01:20 PM
#104
motorsport nut job
Join Date: Dec 2008
Location: ireland
Posts: 31
Likes: 0
Received 0 Likes
on
0 Posts
[quote=Wheely-Boy;6097105]Did make it myself it was alot of work measuring things but I can also make one for you just let me know when you're interested.
Cool, what will it cost with p+p to ireland, and how long will it take?
Cool, what will it cost with p+p to ireland, and how long will it take?
26-11-2012, 04:24 PM
#106
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
[quote=Alan77;6099451]
I'll send you a PM this evening with some details
Thanks! Pm terug
tried to start the car yesterday but I have a fuel problem I think.
Everything works now but it won't fire up. Did put some fuel into the cilinders trough sparkplug holes and re-fitted the sparks plugs.
Then I started the car and it did run goof immediately for a 2 seconds but it died because the fuel was burned, tried to start it after that, nothing. So really looks like a fuel related problem.
Going to check the fuel pressure / pump and other fuel related stuff this evening and see if I can find something.
About the cam blur nothing special but the company doesn't prefer showing it all around I think so that's the reason
tried to start the car yesterday but I have a fuel problem I think.
Everything works now but it won't fire up. Did put some fuel into the cilinders trough sparkplug holes and re-fitted the sparks plugs.
Then I started the car and it did run goof immediately for a 2 seconds but it died because the fuel was burned, tried to start it after that, nothing. So really looks like a fuel related problem.
Going to check the fuel pressure / pump and other fuel related stuff this evening and see if I can find something.
About the cam blur nothing special but the company doesn't prefer showing it all around I think so that's the reason
30-12-2012, 06:59 PM
#108
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
a lot happened since end of November.
The starting problem was solved, this was a simple wrong value in the ViPec ECU thanks to Mark Shead for sorting this out trough email
After that it fired up and runs OK on the base map.
You can find the videolink below from the 3rd or 4rd time the engine was running
Since then I still need to do a few important things.
One of the power steering pipes was leaking so I bought some new o-rings for it
Fitted everything back looks like it solved the problem.
After that I discovered that the steeringrack is leaking so need to take out the steeringrack and buy new sealkit to repair.
The starting problem was solved, this was a simple wrong value in the ViPec ECU thanks to Mark Shead for sorting this out trough email
After that it fired up and runs OK on the base map.
You can find the videolink below from the 3rd or 4rd time the engine was running
Since then I still need to do a few important things.
One of the power steering pipes was leaking so I bought some new o-rings for it
Fitted everything back looks like it solved the problem.
After that I discovered that the steeringrack is leaking so need to take out the steeringrack and buy new sealkit to repair.
04-09-2013, 12:11 PM
#110
I've found that life I needed.. It's HERE!!
Join Date: Mar 2007
Location: The Netherlands
Posts: 1,057
Likes: 0
Received 0 Likes
on
0 Posts
Is the car still alive or completly broken?
13-09-2013, 04:54 PM
#111
Regular Contributor
Thread Starter
iTrader: (2)
Join Date: Dec 2009
Location: Netherlands
Posts: 223
Likes: 0
Received 0 Likes
on
0 Posts
sorry but don't have any updates on the white Cosworth. it is standing still since the beginning of the year due problems and delay.
Sold the GT30 turbo and bought BW EFR 7670 twin scroll but it did take about 10 months before it was ready due quality problems at the BW factory for the EFR series.
The black one is broken, but for restoration not for parts!
I'm currently busy with it with my dad beside all the other work I have in my garage. Will do an update asap with some pics on the black one.
The last owner that sold the car the me in April 2012 lived in Zeeland. He bought it from Max Jacobs who lived in Veldhoven. I think the person you named sold it to him but that's a while ago I think Roy.
Hope to have both Cosworths up and running next year although the plan was to have the white one up and running this year so I could take it to EFE this weekend.
Sold the GT30 turbo and bought BW EFR 7670 twin scroll but it did take about 10 months before it was ready due quality problems at the BW factory for the EFR series.
The black one is broken, but for restoration not for parts!
I'm currently busy with it with my dad beside all the other work I have in my garage. Will do an update asap with some pics on the black one.
The last owner that sold the car the me in April 2012 lived in Zeeland. He bought it from Max Jacobs who lived in Veldhoven. I think the person you named sold it to him but that's a while ago I think Roy.
Hope to have both Cosworths up and running next year although the plan was to have the white one up and running this year so I could take it to EFE this weekend.
06-04-2014, 01:01 PM
#113
Virgin
Join Date: Nov 2013
Location: Holland
Posts: 1
Likes: 0
Received 0 Likes
on
0 Posts
Hi ,
Stephan Great Project one of the few in holland , but u had a lot of bad luck i see !
We bought some cossie parts from you in the past , helix clutch etc .
Im really shocked seeing your body on markplaats ? Please dont tell (us) me your selling this project since it was nearly finished????
Greetings Frank
Stephan Great Project one of the few in holland , but u had a lot of bad luck i see !
We bought some cossie parts from you in the past , helix clutch etc .
Im really shocked seeing your body on markplaats ? Please dont tell (us) me your selling this project since it was nearly finished
???? Greetings Frank
Thread
Thread Starter
Forum
Replies
Last Post
Jack and the Beanstalk
Ford Sierra/Sapphire/RS500 Cosworth
8
15-08-2015 04:27 PM
Jack and the Beanstalk
Ford Sierra/Sapphire/RS500 Cosworth
2
09-08-2015 07:03 PM
