Something different (3 door Cosworth)

[rstoughy]

Wasnt sure where to put this thread so Mods if it's in the wrong place please just say.

Overview,
Basically bought this back in Oct 2006 after my mate had given up on it and gone all Evo.
He originally purchased it from another of my mates who has a few of these in his collection and to be fair it was in pretty good condition having only 38,000miles on the clock, original pannels & paint and a very good history file.

My mate being what he is decided that original was not for him so set out on the hunt for that elusive BHP.

The purchase of a very well known (in the Cosworth scene) and proven engine with all its ancillarys along with a host of other very nice parts meant that the car was now ready for a transplant.
This is where the problem (for him) started.

The engine came with an Autronic ECU and Engine Loom so the original Ford one needed chopping out.
Mate and AN-other promtly done this and the rest is as they say history.

I receive a visit telling me that they can't get the car to run on more than 2 cyls at a time and would i take a look.

Took a look, found the problem and promtly made an offer to buy the whole lot.
Offer accepted, Escort Cossie sold and Evo bought.

So that was back the tail end of 2006. Jan 2007 comes and i'm sitting with a very nice Evo VII FQ and a nice but sorry looking 3 door.
I also started to build myself an extension on the house at that time so the cars took a back seat.

Few years and a few cars later and we are in Jan 2010.
3 door is still in storage and bits of cosworth everywhere but the house is finished and i have now had the CSL for a year so decide that it's time to get this thing on the road.

Looking for a nice figure of around 480-500bhp.

Heres some pics for you.

Picking the car up back in 2006

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC01987.jpg


The electrical nightmare that was awaiting me under the bonnet

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC01990.jpg


Gave it a quick wash to get the bird poo off and stuck it away for a bit

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC01991.jpg


Few weeks later pulled the engine and was left with this

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02008.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02010.jpg


The ECU and Engine loom

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02258.jpg


The standard and modified engines

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02252.jpg


After finding various things i wasnt quite happy about with the engine i decided that id pull it apart and give it freshen up.

Instant gasket round the sump plug anyone :bigcry: :bigcry:

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02265.jpg


Pulled engine to bits ready for some fresh bits

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02332.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02334.jpg


Stripped the head then decided to purchase myself a McRae Motorsport one :smokin:

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02344.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02347.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02346.jpg



That was back in 2007. F/F to this year and this is where we are at


Bare block checked, de-glazed and freshened up

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_1770.jpg


Crank, Pistons re-fitted with fresh bearings, shells, HP Oil Pump etc etc etc

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2320.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2321.jpg


Rest of bottom end built up inc Sump fitted with TCS Gated Baffle

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2334.jpg




Hope i have not bored you too much just thought id share my little project with you.
Will keep this updated as i go.

With a bit of luck i should get it back on the road this year.

Thanks for looking.

[Roland]

Paul, thanks for sharing.

Fantastic job. :thumbs:

[phat///M3]

Nice project you got there :thumbs:

[Bounce]

Keep up the good work mate,well worth it in the end.:thumbs::thumbs:

[mole]

Looking good, keep us updated :thumbs:

[Manny_RDS]

Cossie is an itch I have to scratch one day :drool:

[rstoughy]

Cheers guys :thumbs:

Its been a long road but it is the 4th one i have rebuilt from this stage over the many years i've had them.

It has taken by far the longest though so really looking forward to getting it back out on the road.

For those in the know its going to be running,

Low Comp pistons
McRae Motorsport Grp-a Cyl Head
MA Developments cams / adj vernier pullys
T38 Turbo
Seimens **lb injectors
ST EsCos Inlet manifold and TB
MSD Wasted Spark, Anti-Lag & Launch control using Coil Pack and Air Injectors
Among some other bits so should be a hoot.

Manny,
Has to be done to be beleived.
Once you have been in a genuine 500bhp cossie there's not much that puts the power down in the same way.

[NZ_M3]

Stunning Paul!! Now I can actually picture what you were saying!!

[Dan]

Paul you fooker! I want another one now! :bigcry: :banghead:

Wicked project mate, car looks very nice with the Ambers and RS500 grills, that's how my Escos was :smokin:

I do miss getting filty crawling around under Cossie's every weekend and then putting them back together for Monday morning's commute! :bigcry: :thumbs: Saying that, I hope to god the CSL never goes wrong! :hahaha:

What's the rest of your spec going to be, get some nice AP's on the front, R&B rear kit with 4x4 calipers? You'd do well with an Ahmed beam as well ;) :drool:

I will have another one day, house first, then back to cars! :whistle:

P.s You'll be reaming the hell out of a T38 to get it near 480bhp won't you? Better off getting a T4 and going roller bearing front and rear ala Rainbird's car? :)

[rstoughy]

Thanks Tom :thumbs:

Cheers Dan :thumbs:

Have AP's for the front as well but have not looked into the rear yet.

Ahmed beam would be nice but ££££ :bigcry: :bigcry:

The T38 works really well with the spec.
This is Dave Moss's old engine out of YUM so has proven itself worthy :hahaha:
I might look into some of these GT Turbos though to give me my desired power once i have it up and running again but dont think i could live with T4 Lag :bigcry: :bigcry:


AP's

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC02260.jpg


Dyno Graph

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/Dyno1.jpg

[Dan]

Nice AP's ;)

I think 'in car' Dave's old engine was around 440bhp IIRC?

A full Roller Bearing T4 would easily be on par with a normal T38 I reckon and would pull much harder than a T38 :smokin:

Speak to Harvey (Gibbs) at SCS about an Ahmed beam, they arn't too bad a price... :bigcry: :thumbs:

[rstoughy]

Might look into a modern T4 if they are less laggy. :smokin:

The torque curve on the engine should be interesting coupled to the 2WD set up :whistle:

[Dan]

Might look into a modern T4 if they are less laggy. :smokin:

The torque curve on the engine should be interesting coupled to the 2WD set up :whistle:

They are these days mate, much different to a normal RS500 T4 ;) :smokin:

Actually putting the power down should be interesting to say the least as well! :bigcry: :thumbs: :supz:

[rstoughy]

Small update,
Had a few hrs spare today so got cracking on a couple of jobs.
Fitted my Black wing Grills to the CSL then decided to do some work on the 3 door engine.
Broke out the WRC Gasket and fitted that along with the head.

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2470.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2471.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2473.jpg


Then spent a bit of time and installed the Manifold Studs along with the Manifold and Turbo.

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2476.jpg

http://img.photobucket.com/albums/v447/rstoughy/3%20doors/DSC_2477.jpg


Slowly getting there :smokin:

[Silver Bullet]

Coming along nicely fella:thumbs: