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1988 Sapphire Cosworth 2wd - ground-up build

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Old 10-08-2016 | 08:25 AM
  #81  
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Not updated for a while but there has been plenty going on;

Gearbox and diff are now fitted, the final bits of welding have been completed and with another few hours prepping the body it will be ready for the paint booth.. exciting times!!


Old 10-08-2016 | 08:37 AM
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Old 10-08-2016 | 12:36 PM
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the bodywork looks great!
same for the remaining.
step by step, it's very nice to see you getting there.
keep us posted mate...
Old 10-08-2016 | 04:35 PM
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Top job matey. Nice garage full off cossies.
Old 10-08-2016 | 05:08 PM
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Top job mate. Keep on going.

Nice view in your garage, Cosworth everywhere.
Old 10-08-2016 | 05:51 PM
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Cheers guys!!! Paint next week
Old 22-08-2016 | 09:03 AM
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Well - great weekend for me, we finished the prep Thursday night and the car was transported to the body-shop on Friday.

We got there early on Saturday morning, masked up, got her in the booth and prepared for paint - Nervous times

But all went well - 4 coats of original diamond white -















































Old 22-08-2016 | 12:14 PM
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Just read through this looks great buddy! Can't wait to see the finished product!
Old 22-08-2016 | 12:47 PM
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Cheers mate

Just had word that it's back at the unit now - flat and polish tonight
Old 23-08-2016 | 01:26 PM
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Started to flat and polish last night, should look really good when complete









Old 23-08-2016 | 07:58 PM
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Looking good, you work a lot faster than me !
Old 24-08-2016 | 08:10 AM
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Originally Posted by Mark V8
Looking good, you work a lot faster than me !

lol, cheers mate!!
Old 24-08-2016 | 08:38 AM
  #93  
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Bit more flatting and polishing last night and fitted the roof and window inserts






















Old 24-08-2016 | 11:03 AM
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wow !
it's coming out very well...
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Old 25-08-2016 | 12:30 PM
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Some great work gone into this
Well done
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Old 25-08-2016 | 03:09 PM
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Did you paint the roof and window inserts? If so what black do you use?
Old 31-08-2016 | 08:18 AM
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Thanks guys

No the inserts are original, they have some chipping on the roof bars so I am looking for something to repaint them with. I would say a satin black spray is going to be best but its getting the colour match. I will probably buy a few different makes of spray and see which is the closest on a test piece. I will post on here when I do so you will know which one to buy
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Old 31-08-2016 | 03:46 PM
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Just read this from the beginning and top with you guys have done

Won't be long and she will be motd and on the road
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Old 31-08-2016 | 07:44 PM
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Keep up the good work, great job.
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Old 01-09-2016 | 12:56 PM
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Originally Posted by xr2john
Just read this from the beginning and top with you guys have done

Won't be long and she will be motd and on the road
Cheers, considering it was on the spit 10 weeks ago and I am doing it around a full time job with a few mates I don't think we have done too bad, hit a money wall at the moment though, it has crippled me lol - will be doing less costly things over the next 2 months then hopefully have a final push over the xmas period to have it up and running in the new year
Old 19-09-2016 | 11:08 AM
  #101  
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Few more bits have been done over the past week or so, mainly bolting parts on;

Interior wiring now in place
carpet down
parcel shelf and seat pull's in place
Seats in
Prop connected
Fuel tank in

































Next up; start prepping the doors
Old 24-09-2016 | 09:29 AM
  #102  
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Loving the pics mine is stripped to a bare shell waiting for paint , has been a year so far and I'm so worried about where everything goes , threads like this are mint will really help with the giant jigsaw puzzle ������
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Old 25-09-2016 | 03:39 PM
  #103  
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wow..
amazing job mate..
im doing the same myself at the moment.
be all worth it when its done
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Old 25-09-2016 | 04:26 PM
  #104  
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Looking good
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Old 26-10-2016 | 08:07 AM
  #105  
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Just prepping panels now, bonnet needs to go right back to bare metal as there are some poor repairs and about 7 layers of paint on it and the boot was damaged so the standard saph boot will be modded to take the cossie spoiler.




























Old 28-10-2016 | 05:40 AM
  #106  
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Rivet nuts added to attach the spoiler correctly and got to work on the bonnet - what a mission!!






























Old 28-12-2016 | 04:07 PM
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Coming alone bud, you looking to be driving it for the summer? any more progress reports? keep up the hard work.
Old 29-12-2016 | 04:19 PM
  #108  
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Would have been easier to paint strip the bonnet.

Thats a lot of paint.
Old 29-12-2016 | 06:28 PM
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Top class work there.
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Old 29-12-2016 | 06:53 PM
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Top work. I wish i knew a bit more about doing bodyworl.
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Old 12-01-2017 | 07:13 PM
  #111  
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Originally Posted by twitchyrear
Coming alone bud, you looking to be driving it for the summer? any more progress reports? keep up the hard work.

not done anything on it for 2 months, had other commitments but hoping it will still be on the road mid-summer going to have a big push around May time
Old 12-01-2017 | 07:15 PM
  #112  
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Originally Posted by costina
Would have been easier to paint strip the bonnet.

Thats a lot of paint.
think that is what I will do as soon as I am back on it. having a change round in the workshop at the minute and a few other things going on
Old 12-01-2017 | 08:18 PM
  #113  
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Just read through, looking really good! looking forward to seeing it finished
Old 13-01-2017 | 05:44 PM
  #114  
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Originally Posted by Jez_ST3
... looking forward to seeing it finished
yep, me too!
very good job so far, hope you can get your hands on it soon...
keep us posted mate...
Old 04-08-2017 | 12:04 PM
  #115  
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ok so.... it's been a while since I updated, mainly because we lost our unit and I have had to store the saph in a container for the last 6 months where it would have been a nightmare to work on so I really lost interest. However a double garage came up around 3 weeks ago so I have been back on it full speed and got it settled into its new home

First thing to do was have a new windscreen put in. They guy that fitted it managed to source an original seal for it to which I was mega pleased about;
















Old 04-08-2017 | 12:13 PM
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Then whilst I was waiting for parts I had ordered I carried on with panel prepping and fixing the broken bumper brackets




























Old 04-08-2017 | 12:28 PM
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Had my rear brakes arrive from Gary @ RSClassics so I started getting the braking system in order. I was originally going to use the 1.8L servo and master but not knowing if it was fully up to the job I took this off and went for a twin-cam version as I know Ash was using this on his rep with cossie brakes and it worked well.

I then come to fit the brakes and the caliper carrier would not bolt up over the rear discs, after some investigation and help from Gary we realized that Sierrasrus had sold me the incorrect bearing carriers back when I started the build in 2015 - shame I had already powder-coated them. Fortunately Gary sent me out the correct items. By this time I had decided that although it was a long shot I wanted to drive the car to this year's RS Nationals day so no time for further powder coating, they had to go on for now. I also got the CV's and Driveshafts on;





























Please beware when buying Driveshaft bolts - on ebay there are plenty of people selling sets but they are all the same thread pitch and as I found out the bolts from shafts to diff are a finer thread pitch than shafts to CV. Mine were from Caprisport and half were incorrect.
Old 04-08-2017 | 12:47 PM
  #118  
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Few more parts then turned up so I started the plumbing.

That's about if for now, I will be on it all weekend so hopefully updates will be thick and fast, lets see if I can get to nationals day in it
























Old 07-08-2017 | 12:05 PM
  #119  
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Fair bit of work gone on this weekend, Banbury Flocking have finished my lower dash, sunroof cover and door handles, they will be picked up Wednesday.

Mood Roof have finished my headliner, just got to get my door cards and sun visors to them now.














Old 07-08-2017 | 12:39 PM
  #120  
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Engine and fuel pump wiring now complete
handbrake & Clutch cable in
everything plugged in inside ready for start up
master cylinder plug changed to suit
group A coil wired
HT leads on

its coming together now, just fuel lines, starter motor and fluids and I should be ready to turn they key




















































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