Saph Cosworth 4x4, new race car build update 23/02/17
#1
Saph Cosworth 4x4, new race car build update 23/02/17
After having my xr4x4 for over 10 years and racing it for the last 5 ive finally bought the race car I always wanted a saph cosworth 4x4.
Road car Cosworth 4x4 shells came with a sunroof and only motorsport shells didn't, these are getting very thin on the ground now especially ones that haven't been ragged through a forest!
The only other shells that didn't have a sunroof were police cars again these are rare.
after a flippant comment on a thread I was pm'd on here by cossie09 keith explained that he had an ex police car saph cosworth shell and it was for sale, only problem was it was in Northern Ireland!! Undeterred I struck a deal and this week myself and my dad did a 25 hour round trip to collect the shell.
The plan is to repair this shell, remove all corrosion etc then fit a new cage and then repaint the car radiant red like my xr, then transfer all the running gear from my xr into it.
when that's done I will rebuild the xr into a lower spec yb powered race car for my son to use, he's 15 now so I have a few years to sort it.
I will update this thread as I go but its going to take a while!
My present race car fitted with a 455 bhp cosworth motor and Quaife dogbox
My new shell
First thing I did when I got it home was fit a boot and bonnet to seal it up and stop any more water ingress, oh and my dad kindly washed it!
steve
Road car Cosworth 4x4 shells came with a sunroof and only motorsport shells didn't, these are getting very thin on the ground now especially ones that haven't been ragged through a forest!
The only other shells that didn't have a sunroof were police cars again these are rare.
after a flippant comment on a thread I was pm'd on here by cossie09 keith explained that he had an ex police car saph cosworth shell and it was for sale, only problem was it was in Northern Ireland!! Undeterred I struck a deal and this week myself and my dad did a 25 hour round trip to collect the shell.
The plan is to repair this shell, remove all corrosion etc then fit a new cage and then repaint the car radiant red like my xr, then transfer all the running gear from my xr into it.
when that's done I will rebuild the xr into a lower spec yb powered race car for my son to use, he's 15 now so I have a few years to sort it.
I will update this thread as I go but its going to take a while!
My present race car fitted with a 455 bhp cosworth motor and Quaife dogbox
My new shell
First thing I did when I got it home was fit a boot and bonnet to seal it up and stop any more water ingress, oh and my dad kindly washed it!
steve
Last edited by The Youth.; 23-02-2018 at 09:22 PM.
#2
It Wasnt Me!
Cant have been many cosworth police cars in Ireland, I wouldn't have thought...maybe a pic or two floating around the interweb?
Look forward to seeing it progress!
Look forward to seeing it progress!
#4
10K+ Poster!!
It might be worth contacting the police federation reps as you can bet that the police drivers took pics back in the day. If you can find roughly where it was based then you could go from there, I know a few in the met.
The following 2 users liked this post by Caddyshack:
Mad_Mat (15-01-2016),
The Youth. (15-01-2016)
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#9
PassionFord Regular
iTrader: (2)
Right up till 2002 you could still get the police sapphire s .they were armoured plated with bulletproof glass etc and were nearly 2 ton they had no sunroof s in them.and we had some unmarked cosworth s as well.just in northern Ireland not in southern Ireland....but very hard to get them now.
#10
Too many posts.. I need a life!!
i reckon if you race it you should do it in police livery, that'd be funny a fook.........
full battenburg all over, sponsored by a speed awareness scheme etc...lol
full battenburg all over, sponsored by a speed awareness scheme etc...lol
#11
I've found that life I needed.. It's HERE!!
iTrader: (3)
Right up till 2002 you could still get the police sapphire s .they were armoured plated with bulletproof glass etc and were nearly 2 ton they had no sunroof s in them.and we had some unmarked cosworth s as well.just in northern Ireland not in southern Ireland....but very hard to get them now.
The following users liked this post:
The Youth. (17-01-2016)
The following users liked this post:
The Youth. (17-01-2016)
#22
Finally able to update this thread, its been a busy summer racing my present car and away with my son racing his kart, so I've not been able to do as much on the new car as I would have liked but now its moving forward.
Earlier this year I was able to make a good start on the under bonnet welding, there was a poor patch welded to near side inner wing so I removed that and welded in much better version.
I was then able to get the car on the spit ready to start underneath starting with the offside sill
Taking the outer sill off revealed a mess!
Soon had it all cut out and new metal welded in along with the sill to floor join which needed new metal for the full length of the floor.
Then I welded on a complete out sill
This week I've started on the rest of the offside floor.
That's where it stands at the moment
Steve
Earlier this year I was able to make a good start on the under bonnet welding, there was a poor patch welded to near side inner wing so I removed that and welded in much better version.
I was then able to get the car on the spit ready to start underneath starting with the offside sill
Taking the outer sill off revealed a mess!
Soon had it all cut out and new metal welded in along with the sill to floor join which needed new metal for the full length of the floor.
Then I welded on a complete out sill
This week I've started on the rest of the offside floor.
That's where it stands at the moment
Steve
#25
Ok Time for a recap and update, due to photobucket destroying themselves I'll re upload some of the original pics of the project and show the updates now that the project is moving again.
As Purchased in January 2016
work started on the underside, it needed 2 new inner and outer sills and sills to floor joins
the usual rear beam mounts also needed attention
I purchased a spares car to cut panels from and to provide a good source of clips screw etc I would need, the car was then cutup and scrapped
I cut the spare wheel well out as I'm lowering the boot floor to create a lower flat floor to mount the petrol tank inside
I then fabricated strut brace mounts ( I already had a brace) and cut out and fabricated a removable front cross member
This week ive tackled the rear arches I've not done these before on a saph but its gone well enough, I've removed the double skin on the lip so that the arches can be rolled easier to fit the RL 5 wheels on I use
The front wings have been removed and bolt on version fitted but I've no pics for some reason that brings us up to present day
Also over the past few months I've rebuilt my original race car at a lower spec for my son who's 17 to race this year, the head, turbo gearbox front suspension, 6 degree rear beam have all been removed and more standard stuff refitted still on a T34 greens, coilovers tho !
Steve
As Purchased in January 2016
work started on the underside, it needed 2 new inner and outer sills and sills to floor joins
the usual rear beam mounts also needed attention
I purchased a spares car to cut panels from and to provide a good source of clips screw etc I would need, the car was then cutup and scrapped
I cut the spare wheel well out as I'm lowering the boot floor to create a lower flat floor to mount the petrol tank inside
I then fabricated strut brace mounts ( I already had a brace) and cut out and fabricated a removable front cross member
This week ive tackled the rear arches I've not done these before on a saph but its gone well enough, I've removed the double skin on the lip so that the arches can be rolled easier to fit the RL 5 wheels on I use
The front wings have been removed and bolt on version fitted but I've no pics for some reason that brings us up to present day
Also over the past few months I've rebuilt my original race car at a lower spec for my son who's 17 to race this year, the head, turbo gearbox front suspension, 6 degree rear beam have all been removed and more standard stuff refitted still on a T34 greens, coilovers tho !
Steve
Last edited by The Youth.; 23-02-2018 at 10:00 PM.
#26
10K+ Poster!!
Nice work, I always admire people that get stuck in and do this in the cold outside, my Dad used to do it.
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