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J18 COS Cosworth rebuild and restoration

Old 02-02-2019, 06:35 PM
  #561  
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Old 02-02-2019, 06:37 PM
  #562  
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Old 02-02-2019, 06:38 PM
  #563  
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Old 02-02-2019, 06:41 PM
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Old 02-02-2019, 06:44 PM
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Old 02-02-2019, 06:45 PM
  #566  
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Old 02-02-2019, 06:48 PM
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Old 02-02-2019, 06:50 PM
  #568  
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Old 02-02-2019, 06:52 PM
  #569  
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Old 02-02-2019, 07:05 PM
  #570  
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It's been a while since i updated this, so thought I'd try and use the new picture uploader, now it's either fine or my wifi is shite

I've modified the Koni strut as it was really close to the tyre and any stones picked up were scuffing the cup. I cut it down as the cup is crazy too big for the spring anyway and cozyjeffs dad done a nice job welding it up for me.

uprated clutch - Helix 6 paddle with race cover

i went for the hydraulic clutch conversion in the end. I had been starting to buy the bits a couple of year ago but finally gave in and went for it.
the clutch conversion is amazing, it's as light as the std clutch with cable, with smooth movement and good feedback, I strongly recommend to anyone!

Gearkit - I went for the best of both worlds with Pete Doughty's straight cut 2/3rd but it developed a fault immediately jumping out of second gear. I removed it and dropped it off in October for repair, picking it up today.
hopefully it's all good now
Old 02-02-2019, 07:05 PM
  #571  
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Done a fantastic job well done

I’m at the stage of converting my clutch to hydraulic, done the gearbox side and was curious to how difficult it was to remove the clutch pedal? Does it have to come off with the brake pedal in the full assembly or can you remove it on its own by removing the clip?
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Old 02-02-2019, 07:52 PM
  #572  
james kiely
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serious attention to detail mike ,fairplay
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Old 02-02-2019, 08:05 PM
  #573  
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Originally Posted by Adam-M
Done a fantastic job well done

I’m at the stage of converting my clutch to hydraulic, done the gearbox side and was curious to how difficult it was to remove the clutch pedal? Does it have to come off with the brake pedal in the full assembly or can you remove it on its own by removing the clip?
yes mate it comes off with the brake pedal, 4x 17mm nuts from memory and unplug the brake light switch then it'll come out all in one.

take the circlip off the end and it's all aparant from then on


Last edited by Cossy Mike; 04-02-2019 at 04:05 AM.
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Old 02-02-2019, 08:08 PM
  #574  
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Originally Posted by james kiely
serious attention to detail mike ,fairplay
thanks mate

im a big believer in "If a jobs worth doing......it's worth doing properly"
Old 02-02-2019, 08:34 PM
  #575  
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No corners been cut there mate it looking superb
Old 02-02-2019, 08:53 PM
  #576  
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Lovely work mike.
Old 03-02-2019, 09:44 AM
  #577  
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Originally Posted by Rsmat
Lovely work mike.
Thanks Mat, did you get a reply from Twins about your dash gauge pod?

Originally Posted by tosh
No corners been cut there mate it looking superb
Thank you kind sir
Old 03-02-2019, 09:52 AM
  #578  
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Wow what a stunning saph, lots of nice work gone on there. Underneath looks incredible mate.
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Old 03-02-2019, 02:16 PM
  #579  
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Stunning car this. It's sssssssoooooo clean.
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Old 11-03-2019, 07:56 PM
  #580  
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fitted a set of solid billet cradle bushes from MT Motorsport.

These are awesome, sharpens the gear change right up
Old 11-03-2019, 07:59 PM
  #581  
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Gearbox is all back in and a couple of quick drives around the street, it seems ok.

Roll on April for when I re tax it
Old 11-03-2019, 08:02 PM
  #582  
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Finally got round to picking some Stack gauges up, I've been wanting these for a while. Oil temperature, Oil pressure and AFR gauges
Old 11-03-2019, 08:05 PM
  #583  
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Old 11-03-2019, 08:07 PM
  #584  
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Old 14-03-2019, 11:13 PM
  #585  
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Originally Posted by Cossy Mike

Do you know what colour yellow it is for the Koni's?
Old 15-03-2019, 06:09 AM
  #586  
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Originally Posted by Jules44
Do you know what colour yellow it is for the Koni's?
RAL1037? I took one in to the paint shop and he matched it to this

Last edited by Cossy Mike; 15-03-2019 at 06:10 AM.
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Old 15-03-2019, 10:09 AM
  #587  
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What made you decide to go for the straight cut 2nd/3rd gear option?
Old 15-03-2019, 11:06 AM
  #588  
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Originally Posted by Marc sierra
What made you decide to go for the straight cut 2nd/3rd gear option?
2nd/3rd for me was the better option for me.

The car is around 360bhp at the moment with plans to go BW7064. Anything over 350bhp these boxes are on borrowed time, so I had to do something.

Its a road car to me, so I never launch it and never use it on the track.

I also wanted a bit of refinement so once above 60mph on motorways I have std 5th gear, nice and quiet.

I did weigh up options of a full gearkit but was worried about constant noise and worried I'd hate driving it.

To be honest now it's in, I really like it and the noise doesn't bother me so wish I'd chosen the full kit
Old 15-03-2019, 02:43 PM
  #589  
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I am the same power level but with the standard box, so I also worry a bit whether it will stay in one piece. But I thought it's not only 2 and 3 gear that break, but also the gear on the input shaft, and that will still be standard on your kit. I also want a better gearkit, but I want some other things first... These cars are never finished.
Old 15-03-2019, 03:43 PM
  #590  
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I fitted poly bushes to my gear stick cradle and the difference is like night and day.
Old 15-03-2019, 04:04 PM
  #591  
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Originally Posted by Marc sierra
I am the same power level but with the standard box, so I also worry a bit whether it will stay in one piece. But I thought it's not only 2 and 3 gear that break, but also the gear on the input shaft, and that will still be standard on your kit. I also want a better gearkit, but I want some other things first... These cars are never finished.
From what Pete said 4th is direct drive so not needed. 1st is the strongest gear in there and he not broken one yet in all his boxes he supplies for Rallying.
its normally 3rd that strips first but he's rated this box at 500 now. I do remember him saying that the gear that's part of the shaft is machined off and takes over 2 hours to do?
He tells me there are two Escort Cosworth rally cars in Ireland using the same gearkit, one tarmac spec running 550 and they're going strong

Last edited by Cossy Mike; 15-03-2019 at 07:59 PM.
Old 15-03-2019, 04:51 PM
  #592  
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Originally Posted by Glenn_
I fitted poly bushes to my gear stick cradle and the difference is like night and day.
i didn't want to pay £60 for poly bushes which is why I picked these up.

Have a go of mine if you want Glen it's really nice, well worth changing
Old 15-03-2019, 05:06 PM
  #593  
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Love your cradle on your jack
Old 15-03-2019, 07:57 PM
  #594  
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Originally Posted by Adam-M
Love your cradle on your jack
Had to be done, makes things a bit easier, stops it rolling off the jack
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Old 16-03-2019, 05:29 PM
  #595  
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Originally Posted by Cossy Mike


From what Pete said 4th is direct drive so not needed. 1st is the strongest gear in there and he not broken one yet in all his boxes he supplies for Rallying.
its normally 3rd that strips first but he's rated this box at 500 now. I do remember him saying that the gear that's part of the shaft is machined off and takes over 2 hours to do?
He tells me there are two Escort Cosworth rally cars in Ireland using the same gearkit, one tarmac spec running 550 and they're going strong
4th is indeed a direct drive. But in 2nd and 3rd the drive is going through the gear on the input shaft to the layshaft, so it could still break. But I guess if it is rated at 500 bhp it should be ok.

I noticed 2nd and 3rd are fully straight cut. Are they also available in semi straight cut to reduce the noise? And how much was the kit if I may ask?
Old 16-03-2019, 05:58 PM
  #596  
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Originally Posted by Marc sierra


4th is indeed a direct drive. But in 2nd and 3rd the drive is going through the gear on the input shaft to the layshaft, so it could still break. But I guess if it is rated at 500 bhp it should be ok.

I noticed 2nd and 3rd are fully straight cut. Are they also available in semi straight cut to reduce the noise? And how much was the kit if I may ask?
I know he does semi cut helical gears also, so I don't see why not. He can do the full kit in helical, cost is £5000.
Pete is very accommodating and easy to talk to, send him an email for what you want

Mine was £2000


Last edited by Cossy Mike; 17-03-2019 at 04:03 PM.
Old 16-03-2019, 06:22 PM
  #597  
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Was the £2000 for a complete box or only for the gear kit and came fitting on top? I am not currently looking for something, I just like to know what options are available.
Old 16-03-2019, 07:06 PM
  #598  
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Originally Posted by Marc sierra
Was the £2000 for a complete box or only for the gear kit and came fitting on top? I am not currently looking for something, I just like to know what options are available.
All in mate, VAT and fitting into my box
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Old 17-03-2019, 01:40 PM
  #599  
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Thanks mate, that’s not a bad option then!
Old 19-03-2019, 01:14 PM
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Originally Posted by Cossy Mike


i didn't want to pay £60 for poly bushes which is why I picked these up.

Have a go of mine if you want Glen it's really nice, well worth changing

I'm happy with my poly bushes. I didnt pay 60 quid either. I'm defo happy with the gear change now. It was just soooooo sloppy before.

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