3 DR SIERRA COSWORTH RESTORATION (updated 21/5)

[cossie trav]

Well been as i dont get my lisence back for another 5 months (banned for dangerous driving :oops: ) i thought it was about time to make the car back how it should be , fast and mint . This is going to be a huge project as i am planning to full restore/mod the engine , engine bay and the under side of the car .
well here we go ,

the car/engine bay when i got it ,

http://i83.photobucket.com/albums/j302/cosytrav/Image002.jpg
http://i83.photobucket.com/albums/j302/cosytrav/Image001.jpg
http://i83.photobucket.com/albums/j302/cosytrav/Image000.jpg
http://i83.photobucket.com/albums/j302/cosytrav/3doorcosworth010.jpg
http://i83.photobucket.com/albums/j302/cosytrav/3doorcosworth008.jpg
http://i83.photobucket.com/albums/j302/cosytrav/3doorcosworth007.jpg


broke my 4x4 cosworth and decided to swap all the grp A parts , inlet manifold/fuel rail ,T34 turbo ,pro alloy rs500 intercooler , pro alloy radiator , stage 3 stuff including the L8 ecu over to the 3 dr making it 349 bhp .


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0034.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0033.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0032.jpg
http://i83.photobucket.com/albums/j302/cosytrav/engine.jpg

engine out and found this.

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0041.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0039.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0038.jpg

the bottom end of this is going to have the head off the red top engine because it has a lightened /balanced bottom end , ap racing 6 paddle clutch , low comp pistons and has only covered about 2000 miles .
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0036.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0039.jpg



the engine bay is rusty and dirty so this is where im starting .


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0043.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0042.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0040.jpg



the new TT38 stg 3 turbo which came off a 470 bhp saph . ive took pics of it next to a standard T3 so you can see the size difference . im hoping to get 430 - 450 bhp so the turbo should handle it .


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0077.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0071.jpg

[cossie trav]

Ive been looking to have the head ported and polished , new 3 angle valves , double valve springs and cams . there is a place in Stockport called Ric wood racing who specialise in cnc head machining . I dont know whether to buy a new head that has been ported and polished or get mine done . there not to badly priced at £1170 but thats a bare head . i will be paying him a visit to drop off my old cylinder head to get it done .
i have some pics of the standard block and the low comp block just so you know what im up against .

OLD ENGINE STANDARD PISTONS



http://i83.photobucket.com/albums/j302/cosytrav/IMAG0121.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0116.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0115.jpg


NEW ENGINE LOW COMP PISTONS

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0126.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0128.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0127.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0122.jpg


I am going to have to get the low comp pistons machined to have valve cutouts due to the cams im having being a bit wild .

[cossie trav]

well its been a while since i posted anything about the restoration so here goes .

well the rust on the inner wing turned out to be more serious than just surface rust , check this out .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0205.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0204.jpg


a new inner wing is needed and in true cosworth style there as rare as rocking horse shite and well expensive , ive managed to find out where to get one . germany at a cost of £239 :shock: but i need one so i will have to get one and pay the dosh .
so i cant do anything with the front end yet untill i get the new wing sorted so its time to strip the under neath of the car and repaint everything .

the car did look like this but now looks much worse :lol:

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0055.jpg


all the front suspenion , cross member and steering has been repainted and i with the help of my son have been doing the rear this weekend , the flid who owned the car had waxoiled everything underneath and i mean everything , gearbox , rear beam , diff and everything else underneath . well most of you will be thinking , whats wrong with that it wont rust . well when the idea of waxoil to prevent rusting is good , covering rust with waxoil is bad , and trying to get the stuff of everything is worse . here are some pics to show you where im up to .


the black stuff

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0123.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0110.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0107.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0106.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0105.jpg



the rear beam , drop and dismantle .


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0125.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0124.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0114.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0108.jpg

i will be scrapping the black stuff off for quite some time and will have to paint the beam and all the other parts so it will be a while before i post some more up . so enjoy and i will post when i have made more progress .

[cossie trav]

Did a bit of spraying on the car parts today . It should look like new when these get put back on .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0137.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0136.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0135-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0134-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0133-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0132-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0131-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0130-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0129-2.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0126-5.jpg

hopefully i will be scraping off the underseal tomoz which will be fun . :evil:

[cossie trav]

Well im back on the inner wing , took off the wing and found its been bodged before , the donkey who dodged it had plated over the rust so it came back with avengance .
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0141.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0140.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0139.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0138.jpg

im in the process of getting a new strut and plting the wheel arch , i will post more pics when its done

[cossie trav]

Well here we go again , cant get an inner wing so decided to do it myself , did this at weekend and talk about a pain but it looks much better .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0175.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0177.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0178.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0180.jpg


just waiting for a slam panel and the wing top plate then its done :wink:

[cossie trav]

Ive done a bit more welding on the front end , 2 new wing mounting tops courtesy of beever panels and a new slam panel . I noticed a bit more filler around the drivers side turret , been repaired but its not as bad as the passenger side thank god . it took me all day on sunday to do this so im not doing to bad . Thats enough talking rubbish here are the pics .


The old slam panel , rusty so had to go .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0187.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0189.jpg


How it looked before the wing mount panel was cut down .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0200.jpg

When it was removed .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0201.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0202.jpg


The new wing tops seam welded on with the slam panel placed on to check lining up .


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0198.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0199.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0206-1.jpg
http://i83.photobucket.com/albums/j302/cosytrav/IMAG0205-1.jpg


Just a taster of my welding . Please comment if it looks wrong but it seems to have penetrated enough .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0197.jpg


Finally with the wings placed on (not welded yet ) and the front grill just to double check the linning up .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0203.jpg


Well my plan now is to get some new wings , sort the turrets out and seam weld the full front end and work my way to the back to give it a bit more of a solid chassis like the GROUP A shells . Hopefully it will be done by march / april when the show season starts . I will keep you informed on how its going in a few weeks when i have done a bit more so enjoy .
Thanks Trav .

[cossie trav]

Well i thought id better pull my finger out and do a bit more on the cossie .
Ive ordered the paint and primer to spray under the car and the engine bay so i thought i would finish off the welding and strip the engine bay right back ready for painting . There was another bodged piece on the drivers side inner wing at the base of the strut that needed repairing so i welded in a new piece . ive also stripped out the dash so i could get the wires from in the engine bay inside the car and pull the loom to pieces as ive decided to rewire the engine loom as the wires are brittle and the connections are wore down so anyway here are the pics .


Jonathan helping me sand down .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0335.jpg

the new piece welded in .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0337.jpg

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0338.jpg

All the wires that need tidying up .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0345.jpg

The engine bay nearly ready for paint .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0353.jpg

Im starting it properly now because i want the thing on the road so there will be more updates very soon.

[cossie trav]

back to the underside until i get the paint .

[cossie trav]

well ive done a lot on the sierra since the last time i posted . Ive had to build a new suspension turret due to not being able to get a new one .

ive also decieded to completely resore the car inside and out .

I stripped out the interior today and welded in the turret so all thats left is the wiring to strip out which will be done when i move the car to the unit next week .

Then its rub down to the metal inside and out , get rid of all the rust so its going to be a while before theres any painting or parts going back on the car .

here are the pics so far

The turet

http://i83.photobucket.com/albums/j302/cosytrav/001.jpg

http://i83.photobucket.com/albums/j302/cosytrav/002.jpg

http://i83.photobucket.com/albums/j302/cosytrav/003.jpg

http://i83.photobucket.com/albums/j302/cosytrav/004.jpg

http://i83.photobucket.com/albums/j302/cosytrav/005.jpg

The car how it looks now

http://i83.photobucket.com/albums/j302/cosytrav/006.jpg

http://i83.photobucket.com/albums/j302/cosytrav/007.jpg

http://i83.photobucket.com/albums/j302/cosytrav/008.jpg

http://i83.photobucket.com/albums/j302/cosytrav/009.jpg

I will post more pics when the cars up at the unit .

[cossie trav]

Well its been a while since ive done anything to the cossie but hopefully it should all be starting soon now the cars up at the unit .

All i have done to it since the last post is put the front and rear end on it so i can get it on the low loader to get it up to the unit .

it nearly killed me literally as the jack collapsed with me under the car which caused a bit of a dent in the spare wheel well caused by my shoulder . ouch .

ive bought a load of new parts and will post some pics up when i can get to them as there all in my attic along with half the car .


I think the car could pass for the bumpstop brigade


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0029-1.jpg

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0030-1.jpg

on the low loader

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0031-1.jpg


in its new home

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0032-1.jpg

[cossie trav]

Right here we go major update .

I made an A frame so i could spin the car on its side to clean and weld the underside , Replace any rot with solid steel and finally paint it up .

Ready to roll

http://i83.photobucket.com/albums/j302/cosytrav/DSC00086.jpg

http://i83.photobucket.com/albums/j302/cosytrav/DSC00089.jpg

Well the black stuff and underseal is finally off thank god , its taken me a week of 5.30pm to 12am working hours but its finally cleaner .
Theres more holes what have been bodged up with filler and fiberglass and will soon be solid steel .
Been up there since 11am and got most of the holes replated by welding plates thet go in the original body work and not over it as it looks a mess.
Ive also put in the right hand side rear inner and outer arch as that was rotten to .
Pic time .

Before

http://i83.photobucket.com/albums/j302/cosytrav/DSC00089-1.jpg


After

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0058-1.jpg


Hole time :wall:

Before

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0071-1.jpg

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0072.jpg

After

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0078-1.jpg


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0079-1.jpg

Before on the arch


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0061.jpg

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0060.jpg

Old arch chopped out

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0074.jpg

New inner and outer arch in

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0080-1.jpg

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0082.jpg

Hole in rear chassis leg

Before

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0063-1.jpg

After

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0081.jpg


Other chassis leg i did last year

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0064-1.jpg

Hole in the floor repaired last year

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0066-1.jpg

Ran out of gas for my welder so i still have these to repair .

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0062.jpg


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0070-1.jpg


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0059.jpg


Hopefully get these welded next week . Flip the car the other way and replace the other inner and outer rear arch . Then etch primmer , seam sealler by weekend .

Well ive had a good day welding some more holes .

Finally finished one side , going to flip it over during the week and attack the other side . The other side isnt to bad but its having new inner and outer arches and any holes re plated .

Pic time .

From this


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0059.jpg



to this


http://i83.photobucket.com/albums/j302/cosytrav/024.jpg

this


http://i83.photobucket.com/albums/j302/cosytrav/011.jpg


to this

http://i83.photobucket.com/albums/j302/cosytrav/035.jpg


this

http://i83.photobucket.com/albums/j302/cosytrav/IMAG0060.jpg


http://i83.photobucket.com/albums/j302/cosytrav/IMAG0061.jpg


to this


http://i83.photobucket.com/albums/j302/cosytrav/036.jpg


Their was a bit of rust on the rear of the inner arch .Now solid steel .


http://i83.photobucket.com/albums/j302/cosytrav/027.jpg

And finally seam welded one of the turrets

http://i83.photobucket.com/albums/j302/cosytrav/031.jpg


Now looks like this .Ready for the other side .

http://i83.photobucket.com/albums/j302/cosytrav/037.jpg

There will be more next week folks .

Thanks for reading , How to make a 21 yr old rust bucket solid .

[cossie trav]

Anyway been busy doing a bit more metal fettling over this weekend and a bit more waxoyl/under seal removing . Ive only one more hole to weld up then its cleaning time for the underside and engine bay so i can get it ready to paint hopefully by this time next week it should be primed up .

Here you go peeps more pics ,

A nice hole in the inner and outer sill which was a right pain to repair .

http://i83.photobucket.com/albums/j302/cosytrav/033-1.jpg


Now been replated inside , outside

http://i83.photobucket.com/albums/j302/cosytrav/017.jpg


http://i83.photobucket.com/albums/j302/cosytrav/016.jpg


New inner and outer arch

http://i83.photobucket.com/albums/j302/cosytrav/035-1.jpg


http://i83.photobucket.com/albums/j302/cosytrav/032-1.jpg


old lip on the end of the sill


http://i83.photobucket.com/albums/j302/cosytrav/031-1.jpg


new lip

http://i83.photobucket.com/albums/j302/cosytrav/015.jpg

Seam welded the strut


http://i83.photobucket.com/albums/j302/cosytrav/020.jpg


Some pics of last years welding repairs that i did .

http://i83.photobucket.com/albums/j302/cosytrav/019.jpg


http://i83.photobucket.com/albums/j302/cosytrav/021.jpg


All the small repairs are done in galvanised plate so they shouldnt rust again thats about 5% of the car that is now galv :rlmao: :rlmao: :rlmao: .

More to follow . Nearly ready to paint .