3dr door sierra cosworth rep - zetec turbo
 

Hi guys aint been on here for a while, am half way through my latest project and is when I like to start a thread so here goes.

I bought a 3dr shell (red one in pics below) and was the cleanest one I found. I then found a full genuine 3dr cosworth kit , bumpers,arches,skirts and spoiler.

I had my eye on a few bonnets but they were silly money so I bought another 4x4 sierra as it had a genuine bonnet (over the top I know) I sold the engine out of it which almost coverd the amount for the car so was happy with that. I also got 2 of the mintest front seats I had seen and the dash was really tidy. I took the 4x4 front subframe setup as had all been polybushed so turned out good buying a whole car just for a bonnet :roll:

Cutting the rest short all my bits sat around for a year or so as didn't have the space to do it but moved into a bigger workshop 6 months ago so work started on the red shell straight away.

I go to classic ford every year and have always taken an old ford and I'm trying my best not to let the 2014 show be any different.

On with the pics

I spent a few weeks going round the outside sorting the bodywork as I wanted it in primer asap, I cant find any earlier pictures as I lost my phone, some work had already been done
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I spent a while carefully unpicking the front wing of the 4x4 as it was mint
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This was the heart of the workshop keeping us nice and toasty, waste oil burner
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Then I put abit of black base over everything for rubbing down purposes
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This is the next day and pushed outside
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I took everything from underneath of the 4x4 and used them so I spares and Had my rear beam, trailing arms and other bits sand blasted then gave them a couple of heavy coats of 2pac primer then 2 heavy coats of 2 pac black
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Gave them a couple of days then started to fit things back together :grin:
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Everything was stripped from underneath ready for cleaning and painting, couldn't help but offer the kit up
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I then had a bad couple of weeks and just decided fuckit the underneath is getting done in black shutz not a heavy thick coat just a light dusting. I actually like it as the car is never going to be concourse and it will always be just a rep. I didn't get any pics of that but I then got on with building up the rear end

Lsd diff from the 4x4 :grin:
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I'll up load more pics tomorrow as still got plenty.

will also give full details of engine spec and power I'm aiming for.

Not the best of pictures so far but so much hard work has got it this far and I'm happy with the results

Any comments welcome. thanks

Not a bad job so far keep up the good work

looking great

Looks good il keep an eye out on this :top:

Cool project matey. Keep up the good work.

Nice project fela

right on with a few more pics and info on whats happening engine wise.

I made all new brake pipes front to back (rear in picture)
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Then was the time for abit of colour.....

moonstone :grin:
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I rolled the front end from the 4x4 outside for a clean off and ready to go back on as was all either new or mint with polybushes

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A few days later I started fitting the engine bay back up with nice shiney clean parts
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A few more bits back from being blasted and painted
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had a 2.0l zetec flywheel skimmed flat then cosworth clutch cover bolts drilled and tapped into it, new cosworth paddle clutch so no slippy slippy
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The next night I got carried away and something happened
2.0l zetec with focus rs pistons and rods
I had to make engine mount up (spent a while getting the engine sat right)
Also made my own alternator bracket so it cleared my inlet manifold
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Was waiting for my heavy duty valve springs to arrive and couldn't wait so rested the head in place and with 2 other bits, T4 turbo sat on a 200sx tubular manifold I modded the bottom half of a rover inlet with 100mm square box section and the edges machined down to make it look less boxy, 80mm throttle body with fiesta turbo tps mounted on the side.
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Then back to the paint booth and painted the tank
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few bits arrived with the posty
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rs500 clocks that I've been saving for a few years :grin:
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started making a few bits (water pipes etc)
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oh nice
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Then these arrived
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saw this on facebook thought it was funny
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This will be 2nd in charge controlling things, ms2 v3
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along with these emptying the tank
siemens deka 650cc injectors
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Slighty jealous on the clocks, that zetec looks tidy in that bay

I then fitted my new valve springs, got head skimmed then bolted it down :grin:
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I fitted everything else on the engine and wired in the ecu :DD: and yes the bloody thing didn't start :cry: I spent a few days going over it and found a broken wire at the main ecu plug and it fired straight up, I was a very happy bunny

small crap vid - runs abit ruff but it will do till I can get it mapped

http://i222.photobucket.com/albums/d...ps99506649.jpg

Can anyone recommend somewhere to get megasquirt mapped on the rollers? am in south kent but I WILL TRAVEL ANYWHERE cos I'm dedicated in getting this done for classic ford oh and my sanity as this car has taken so much time and effot as have done most of it on my own I need to have it done before it kills me lol

Then thought I'd drive it out of the workshop for the very first time, I even had an audience then realised my mis match of clutch wasn't right the pinto clutch bearing needed a spacer so I walked down a few workshops and I asked my engineer friend to make up a 15mm spacer, I carefully welded the spacer to the blearing without overheating it
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After fitting the spacer the clutch worked an absolute treat was really happy and theres no way its going to slip on boost as its got the typical paddle judder when pulling away but if your seeing that then pulling away like a pussy :DD:

But to fit the spacer I had to do this :cry:
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while the engine was back out I gave my home made remote thermostat housing a tweak and now works perfect with the water return for the heater matrix and my threaded nut for temp sensor
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Theres probably a whole day of thinking chopping and welding just on this one piece
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fancy stainless clips
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custom 3" downpipe I made, going to be heat wrapped
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genuine ford timing belt
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I've got a few more bits I want to do tomorrow so will keep you all updated step by step

Oh and plans are, I want 350hp out of this at maybe just over a bar of boost (shouldn't be a problem with my setup right?)then next winter i'll take it out and put some shiney strong internals in it.

Thanks for any comments its what keeps a man like me sane as the misses couldn't care less and thats why I understand that picture of the bird tied up further up ^^ lol

What part of Kent are you from ?

Steve

Some nice work gone into this.
well done :grin:

Hi Steve I'm from deal, we've already met. I came to a Pf rolling road day over near Canterbury a few years back. I was in a mk6 escort with a zetec turbo engine, the clutch slipped as it came on boost if you remember.

I have problems remembering what I done yesterday let alone 4 or 5 years ago lol

Get yourself along to this meet

https://passionford.com/forum/south-...april-3rd.html

Steve

Top work fella. :clap:

looks good :clap:

Cool project :D

Awesome! I'd go for base spec looks though, proper sleeper!

Looking good

Cool project!

Nice one.
Was looking to see what water rail you had fitted
What starter will you be fitting????

aha sparkys a good friend of mine, didn't make it to the last few meets but will be there for the first so see you there

Thanks I was on your thread the last time I was on here and that's where I got a rough power estimate from for mine

ye I spent a while looking at water rails and I couldn't find one to match everything I wanted to use as some didn't have water return for heater matrix and all of the sat in the wrong place for the top mount exhaust manifold I'm using so just made my own.

Am using a 1.8 cvh sierra starter on an mt75 box and works perfect.


Thanks to all for comments :grin:

Nice project. Cant beat a Moonstone 3dr...

What going on with this? Any updates?

Some nice bits going on that zetec

any updates?

what gearbox are u using lad?

Wow that engine is coool.

I broke my Zetec turbo engine up if you need any parts.

Nice car and tidy Engine install.

Si, What do you mean you are breaking the turbo engine, why is that and whats the plan???

Change of direction ;)

What's going in?????

whats the update on this and what gearbox are you using?

looks like a 2wd mt75 fitted to twincam sierras

Nice project, should be pretty quick

Gonna be a nice one mate

Hi guys it's been a while, as I'm sure you can guess it never made it classic ford last year I ended up taking a pink mk4 escort cab:oops: .

Classic ford 2015 is less than 2 months away and I have been a busy bee. The long overdue update is here. Pictures...

New purchases
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A very pretty new sump as wernt to keen on the cvh one
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Little bits.. I'm going to replace the Cosworth part of the decal with a zetec sticker in the same font. Shinny new wheel nuts and SARD fuel pressure regulator.
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Then the pictures you been waiting for I finally got some colour on it. I spent a long time blocking the primer down and it's perfectly straight and I'm really happy with the outcome.
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I'm a little bit further than this I will upload more pictures of how far I am tomorrow.

Comments welcome

Thanks for looking

lovely paint job mate, do u do it for a living? Best colour aswell

Looking good.
Coming along nicely

good work and best colour

Top work fela looks great

Paint work looks a fine job!