2wd saff cos.... More power :-)

[bil n kel]

hi there this is my 2wd sapphire cosworth
the day i picked it up
standard engine with stg3 and turbotechnics stg2 t3



unfortunately the fun didn't last long (7days)
after a play with an impreza i was slowing down and stopped at a roundabout when i noticed i couldn't see out of my back window. this would be because the turbo had just sh*t itself  
upon removing the turbo i then see water had been pissing out the side of the head gasket. so of comes the head and taken to a reputable engine builder. they informed me it had bad corrosion to the water jackets but was repairable. so i said " just make it like new again" 16 new valves, guides and complete freshen up. i then go buy a t34 and rs5oo intercooler. me and my brother wingy put it back together. later that night we driving about a boost pipe comes off(wingy ). i get out to put the pipe on and hear a hissing noise. i then notice what looks like water coming through a crack in the side of the head(not very happy).
i phone the company up and let rip the next day to which they reply "bring the car in and we fix it for you" ok so i take them rthe car. later that day i get a phone call "its all sorted mate come pick it up" i go pick it up and they only have stuck JB metal weld to the side of the head   when they put the new studs in they had done them up too tight and this caused the crack.

[bil n kel]

at this point i thought bollocks to it, its working for now lets go have some fun couple of months of abuse later and the bottom end lets go on 24th dec
luckily i had just picked up a bargain
200 block with low comp pistons and a 1 skim 4x4 head all just rebuilt not even put together yet.
guess what i was doing boxing day(wasn't allowed to xmas day )

so out comes the engine

and in with the new


couple of weeks go by running it in and then the headgaket starts showing signs of going
"sod this i can't be arsed to fix it" i say to wayne
to which he replys "take it to joe stevens and get him to do it"
off we take the car down to essex and drop it off. one problem, he's on holiday. not to worry ben is there and i tell him the headgasket is gone. couple of days later joe phones " your headgasket wasn't gone, the radiator was fooked"

[bil n kel]

problem was i told ben the gasket was gone so he took the head off never mind good reason for wrc gasket
 i then take car to christian at APT for the norfolk rsoc rr day.

i wasn't too pleased with the result it should of made more than that upon investigation i see it wasn't hitting full boost. wayne then finds a dodgy amal valve connection. that fixed and we're flying again
couple of years go by and considering i use the car for work everyday never really have many problems, only minor issues like sensors packing up. i replaced the gearbox when that started to whine in 3rd. so i think "ah time for uprated clutch". evrything fines again till the diff starts to whine. never mind carry on with the abuse till it breaks .
after a trip back down to joe, decide more boost is needed so its set up to run 27psi peak dropping to 24psi.
the diff didn't like that and luckily broke right outside my house. a 2nd hand 1 was fitted so i could use it and never got round it getting a new one.
any way that roughly brings it up to where it is today
quick spec
standard 4x4 head
200block with low comp pistons
stg 3 conversion
t34 .48 turbo
grp A breather
rs500 intercooler
ap racing clutch
gaz coilovers
drilled and gooved discs with ebc red stuff pads
set of 5 compomotive mo's in grp A fitment 17x8 et33

[bil n kel]

coilovers not fitted in these pictures

[bil n kel]

at the minute the car is in the garage with no radiator ( new one turned up today) or intercooler. with everything unplugged/ disconnected ready for the engine to come out. the headgasket has been showing signs of starting to go and after a recent blast with a couple of astra vxr and a gsi turbo it has gone
that is a blessing in disguise however as i've been wanting to do some stuff to it for a while now but with the price of petrol i've not been able to

on the list is
bigger brakes
fitting evo 8 brembo 4 pot calipers with mk1 focus rs discs
converting the rear to 4x4 spec

replace rear diff with newly purchased one

engine going to joe stevens @ bluesprint
bottom end freshen up inc new std comp pistons with valve pockets
10 long studs
.63 exhaust housing
32psi
grey injectors
possibly bd14 inlet cam
mapped on engine dyno

will get some pics at the weekend when stripping down.
i am gutted it will be the first time my car has missed a show it looks like me and kelly will be taking the ka

[cozmeister]

We definitely need pics of it being stripped and built up again

Did the dump valve come off at some point - the video has a distinctively chattery soundtrack.

[bil n kel]

We definitely need pics of it being stripped and built up again

Did the dump valve come off at some point - the video has a distinctively chattery soundtrack.

i been asked to work saturday so might not get anything done this weekend as going to world superbikes at silverstone on sunday
yes the dump valve was off that week    it does my head in after a while so i take it off. normally at the side of the road somewhere people must drive past thinkng typical ford broke down, then i pass them in a couple of seconds later>

[RST-Steve]

Interesting read this, keep the updates coming

[cozmeister]

i been asked to work saturday so might not get anything done this weekend as going to world superbikes at silverstone on sunday
yes the dump valve was off that week    it does my head in after a while so i take it off. normally at the side of the road somewhere people must drive past thinkng typical ford broke down, then i pass them in a couple of seconds later>

It's nice to know it's not just me that does that

I get frowned at by the missus for not making my mind up!

[bil n kel]

told my boss today i ain't cgoing in tomorrow cos i need to get the cossie done. its doing my head in driving round in the rover metlow

[cozmeister]

They're like driving cardboard boxes aren't they.

The ONLY time I ever drove one, I was genuinely scared for my life.  Quite why I went down the dual carriageway at 70 is beyond me - I was cacking myself the whole way!

[bil n kel]

its a 1.4i auto its quicker than the ka though and thats with a motorbike in the back as well

[Daz-cos]

this is turning into a good project. Be good to see the whole rebuild step by step.

[massivewangers]

Love the old skool comps I must say.

Though if it was me, as it's 2WD, I'd paint the comps silver and fit the ambers back on 

[RST-Steve]

Ambers are cool

[bil n kel]

i took the brakes off at the weekend and 1 off the pistons was stuck in the osf caliper. i had this problem before when the pads got low. i have free'd it off and i've also got some ds2500 pads which i bought about 2 and half yrs ago and lost and have now found again which brings me to the brake conversion. kelly wants me to put escos wheels back on and i've always loved white saffs slammed on escos rims but thr 330's they won't fit under them   the mo's aren't in the greatest condition as they came off a rally car and 2 of the 5 have been welded/repaired and i fancy a bit of a change as every saff cossie has comps

pics with escos wheels

[cozmeister]

If they're the same Comps as Churchy's got, he might have them off you to replace the wheel he 'bent'.

My faves are 17 inch TSW Hockenheims - look like porn on a Saff

[RST-Steve]

They're different Chris, Churchy's are the newer style 5 spoke

[Emma]

If they're the same Comps as Churchy's got, he might have them off you to replace the wheel he 'bent'.

He's already bought a brand spanking new one!

[RST-Steve]

verrrrrry nice!

[massivewangers]

If they're the same Comps as Churchy's got, he might have them off you to replace the wheel he 'bent'.

My faves are 17 inch TSW Hockenheims - look like porn on a Saff

I think I know of a set of 8x17s for sale

Bil, are the Comps useable? Straight? For sale? 

[cozmeister]

He's already bought a brand spanking new one!

Excellent

[bil n kel]

I think I know of a set of 8x17s for sale

Bil, are the Comps useable? Straight? For sale? 

they are useable i've had them on here for about 3yrs. none of them are buckled but all have flat spots to fit them i had to change to longer grp A studs cos the wheels are grp A fitment et33

[bil n kel]

 



down to essex next saturday to drop it off  try and get the other stuff done next couple of weeks. i've decided to keep with the standard size brakes for now so its just a case of having a clean up and fitting the new parts i've bought. hopefully have it back out by september ready to kick some impreza ass

[massivewangers]

they are useable i've had them on here for about 3yrs. none of them are buckled but all have flat spots to fit them i had to change to longer grp A studs cos the wheels are grp A fitment et33

In the words of the great Terry Tibbs...."Talk to me!"

How much mate? Could I try one on my car to see how the offset looks?