MA Developments Sapphire Cosworth 600+ HP 4x4
17-12-2016, 08:43 PM
#81
ok the complete engine was in a few weeks ago and tried to spend some time in the evenings to build everything around the engine as we would like to fire up the car before of the end of the year.
Looking forward to a 2 week Christmas holiday so should be no problem to have atleast the engine running by then
How it looks now
Also designed and fabricated this "timing belt tensioner failure bracket" to prevent the tensioner rotating if the nut/stud ever comes loose.
This happened in Augstus 2015 while mapping so that's the reason for fitting this.
And bought some oil for the Oppliger gearbox
More updates in the next couple weeks...
Looking forward to a 2 week Christmas holiday so should be no problem to have atleast the engine running by then
How it looks now
Also designed and fabricated this "timing belt tensioner failure bracket" to prevent the tensioner rotating if the nut/stud ever comes loose.
This happened in Augstus 2015 while mapping so that's the reason for fitting this.
And bought some oil for the Oppliger gearbox
More updates in the next couple weeks...
17-12-2016, 09:13 PM
#82
PassionFord Post Troll
I love the tensioner fail safe idea you should make a few of them if defo be interested in one. Lovely car btw!
17-12-2016, 10:03 PM
#83
PassionFord Post Troll
Nice work bay looks great 
I'd also be interested in one of those brackets any chance you'd make some?
I'd also be interested in one of those brackets any chance you'd make some?
18-12-2016, 10:55 AM
#85
PassionFord Regular
i'm not interested un buying it, just came here to say that i love that kind of mad genius ideas.
truly inspiring man, you did great
!
truly inspiring man, you did great
!
28-12-2016, 08:40 AM
#86
thanks for the positive feedback on the tensioner bracket..
It took me a while to figure out how the best way was too lock the tensioner and which point to use (bolt from thermostathousing in the end)
The reason I won't make them and sell them is because they're different for each engine since the head/block/gasket thickness is already a factor how far the tensioner needs to be rotated to get correct tension.
A slotted hole is a solution but there is no room for a slotted hole around the thermostathousing bolt
Otherwise it was an option to make a few of them.. And btw also the thermostathousing needs special modification on the milling machine to accept the bracket, which makes it also less interesting to send over the thermostathousings for modification
Having a 2 week Christmas holiday now so it's looking that the car can be started by the end of next week
It took me a while to figure out how the best way was too lock the tensioner and which point to use (bolt from thermostathousing in the end)
The reason I won't make them and sell them is because they're different for each engine since the head/block/gasket thickness is already a factor how far the tensioner needs to be rotated to get correct tension.
A slotted hole is a solution but there is no room for a slotted hole around the thermostathousing bolt
Otherwise it was an option to make a few of them.. And btw also the thermostathousing needs special modification on the milling machine to accept the bracket, which makes it also less interesting to send over the thermostathousings for modification
Having a 2 week Christmas holiday now so it's looking that the car can be started by the end of next week
06-01-2017, 05:23 PM
#94
some updates.. made a bracket for the 9" inch diff on the milling machine
Started with a big block of alloy
Drilling some holes to hold the block to fixture plate
Let the machine do it's work by milling out the contour of the bracket
Powerflex bushes
All fitted up
Then I bought and refurbished some 2wd driveshafts to fit the 9" inch diff
After that the exhaust needed some slight modifications and new brackets because of the 6 degree rear beam
Making some manual oil pressure
Getting oil out of the turbo feed so now most of the engine should have been supplied with oil..
Some random pictures
Started with a big block of alloy
Drilling some holes to hold the block to fixture plate
Let the machine do it's work by milling out the contour of the bracket
Powerflex bushes
All fitted up
Then I bought and refurbished some 2wd driveshafts to fit the 9" inch diff
After that the exhaust needed some slight modifications and new brackets because of the 6 degree rear beam
Making some manual oil pressure
Getting oil out of the turbo feed so now most of the engine should have been supplied with oil..
Some random pictures
06-01-2017, 06:09 PM
#95
10K+ Poster!!
Wow, that is clean
10-01-2017, 07:08 PM
#99
thanks for the reply's ! 
The engine has also started for the first time since it's been repaired everything looks and runs good and still need to sort out a few things before I can do a little test drive in the street..
After that it will be out for MOT and laser alignment in the upcoming 2 months and then planning a mapping session by Mark Shead when the weather gets better and dry hopefully somewhere March / April
Ignore the loose hoseclamp on the turbo inlet
The engine has also started for the first time since it's been repaired
everything looks and runs good and still need to sort out a few things before I can do a little test drive in the street..After that it will be out for MOT and laser alignment in the upcoming 2 months and then planning a mapping session by Mark Shead when the weather gets better and dry hopefully somewhere March / April
Ignore the loose hoseclamp on the turbo inlet
01-04-2017, 07:40 PM
#104
unfortunately the car is not ready yet to be mapped by Mark.
After the first startup I also selected gears with the car on the ramp and wheels off the ground.
No drive to the wheels, inspected clutch and it did work fine so the problem had the be in the gearbox.
Taken the gearbox out to be shipped and inspected by Bara who had build the Oppliger gearbox.
He did find that the main shaft was broken but had no idea why, it was a strange straight cut were it was broken and the box had 0 miles on it so it is under warranty.
He got supplied a new mainshaft but it didn't fit good so the complete gearbox is now at Oppliger to fix but it seems this takes alot of time to be ready
I might fit my spare Oppliger gearbox for a while to get the car MOT and alignment but that box is std. ratio and the broken one is close ratio which I prefer and Mark also so hope to have it back soon from Oppliger
then I can get things rolling
After the first startup I also selected gears with the car on the ramp and wheels off the ground.
No drive to the wheels, inspected clutch and it did work fine so the problem had the be in the gearbox.
Taken the gearbox out to be shipped and inspected by Bara who had build the Oppliger gearbox.
He did find that the main shaft was broken but had no idea why, it was a strange straight cut were it was broken and the box had 0 miles on it so it is under warranty.
He got supplied a new mainshaft but it didn't fit good so the complete gearbox is now at Oppliger to fix but it seems this takes alot of time to be ready
I might fit my spare Oppliger gearbox for a while to get the car MOT and alignment but that box is std. ratio and the broken one is close ratio which I prefer and Mark also so hope to have it back soon from Oppliger
then I can get things rolling
Last edited by Albertodelgado; 01-04-2017 at 07:42 PM.
01-04-2017, 08:40 PM
#106
10K+ Poster!!
Sad to hear, I hope they all look after you
29-04-2017, 05:33 PM
#109
gearbox came back from Oppliger and fitted the same day last week.
Everything did look fine and works OK now although a small oil leak on the gear oil.
Yesterday I went out for a little longer testdrive for the first time, everything went well except for another new oil leak this time from the transfer housing oil.
It came out the top breather hole from the transfer housing.. I filled up both gearbox and transfer housing oils to the correct amount as the manual said, but when I opened up the filler plug of the transferhousing oil to check the level it was too full, almost 0,5ltr came out so that's not good since that means it was 0,5 ltr over the max limit, this also explains why it is leaking out of the breather hole since it was to full.
Reason seems that the gear and transfer housing oil are mixing maybe due a bad seal inside
and since the transfer housing is lower and has less oil this get's filled up.
Going to discuss with Bara monday but the box is going back to him again probably asap for check/repair. He's providing top quick service every time to help me out but Oppliger fails to answer questions from him and also still doesn't pay him and me to cover the expensive shipping costs for shipping the box in a crate to UK / Italy etc, no good service...
Everything did look fine and works OK now although a small oil leak on the gear oil.
Yesterday I went out for a little longer testdrive for the first time, everything went well except for another new oil leak this time from the transfer housing oil.
It came out the top breather hole from the transfer housing.. I filled up both gearbox and transfer housing oils to the correct amount as the manual said, but when I opened up the filler plug of the transferhousing oil to check the level it was too full, almost 0,5ltr came out so that's not good since that means it was 0,5 ltr over the max limit, this also explains why it is leaking out of the breather hole since it was to full.
Reason seems that the gear and transfer housing oil are mixing maybe due a bad seal inside
and since the transfer housing is lower and has less oil this get's filled up.Going to discuss with Bara monday but the box is going back to him again probably asap for check/repair. He's providing top quick service every time to help me out but Oppliger fails to answer questions from him and also still doesn't pay him and me to cover the expensive shipping costs for shipping the box in a crate to UK / Italy etc, no good service...
30-04-2017, 10:34 AM
#110
Advanced PassionFord User
Heard this too many times about the oppliger service/customer care, that's why I'd never buy anything from him
Cheers Paul
Cheers Paul
30-04-2017, 04:14 PM
#111
10K+ Poster!!
I found the best way was to ask where my item was on each of his Facebook posts, he hated it and got angry but I was clear that I was not going away....I also phoned emailed and texted constantly.
30-04-2017, 08:49 PM
#112
PassionFord Post Troll
Build qaulity on this car is something else
01-05-2017, 07:40 AM
#113
Too many posts.. I need a life!!
I have no interest in using this company.
The following users liked this post:
lee2cossies (01-05-2017)
01-05-2017, 05:12 PM
#115
PassionFord Post Whore!!
02-05-2017, 07:14 PM
#117
Advanced PassionFord User
14-05-2017, 08:10 AM
#118
thanks for the replies
Still no reply from Oppliger, he said to Bara that he was contacting me for collection of the gearbox for repair but more then 1 week has past and no contact yet, horrible after care indeed
In the meantime I've fitted my new spare Oppliger gearbox with std ratio which I don't prefer but for now it's working OK so far without leaks or problems.
MOT and wheel alignment has been done last week without problems so finalizing the mapping @ Mark is planned upcoming Friday 19th May and if weather is not good it will be shifted onwards trough the days after when the weather is OK for mapping
Testing flow of fuelpump to make sure it delivers enough fuel comparing to flowchart of pump
Still no reply from Oppliger, he said to Bara that he was contacting me for collection of the gearbox for repair but more then 1 week has past and no contact yet, horrible after care indeed
In the meantime I've fitted my new spare Oppliger gearbox with std ratio which I don't prefer but for now it's working OK so far without leaks or problems.
MOT and wheel alignment has been done last week without problems so finalizing the mapping @ Mark is planned upcoming Friday 19th May and if weather is not good it will be shifted onwards trough the days after when the weather is OK for mapping
Testing flow of fuelpump to make sure it delivers enough fuel comparing to flowchart of pump
26-05-2017, 09:58 PM
#120
thanks mate! It isn't the cheapest oil indeed but for me it does the job and works OK.
The car was mapped and finished yesterday in the UK by Mark He's done a great job on building the engine and mapping it, it's exactly how it should be now so very happy customer
Also got on the dyno with it and it made 632 hp 526 lb/ft as Mark expected, this was with high 55degrees! inlet temp since was with a pretty hot day also in the dyno which took power down.
With lower inlet temp on cooler day it should do 660/670hp but these are just numbers and the most important thing is how the car peforms and this is really awesome.
Now drive the car and wait if the short ratio box from Oppliger ever returns from it's second repair which transforms the car and accerelation even more
Here's some pics below from the day
Fueling up car for last time
Arrived at Marks workshop
High boost graph
Low boost graph
Dyno
Back to leave the UK trough Dover
Some nice food after succesful day
Dyno video. Always more impressive when standing next to it when dyno'd when checking to video afterwards but just to get the idea
The car was mapped and finished yesterday in the UK by Mark He's done a great job on building the engine and mapping it, it's exactly how it should be now so very happy customer
Also got on the dyno with it and it made 632 hp 526 lb/ft as Mark expected, this was with high 55degrees! inlet temp since was with a pretty hot day also in the dyno which took power down.
With lower inlet temp on cooler day it should do 660/670hp but these are just numbers and the most important thing is how the car peforms and this is really awesome.
Now drive the car and wait if the short ratio box from Oppliger ever returns from it's second repair which transforms the car and accerelation even more
Here's some pics below from the day
Fueling up car for last time
Arrived at Marks workshop
High boost graph
Low boost graph
Dyno
Back to leave the UK trough Dover
Some nice food after succesful day
Dyno video. Always more impressive when standing next to it when dyno'd when checking to video afterwards but just to get the idea