Crystal Blue make-over

[Scouse]

Seeing as nearly everyone has a resto in hand I thought I would start putting mine on here.

Not a big a project as some of you, but thought I would share my "ups and downs" associated with my Cosworth.

As most of you will know, I am having the engine rebuilt by Clint. No4 big end went and it was making a terrible noise! Anyway, the crank has been re-ground and new pistons (oversize) have been fitted along with another con-rod for No4 piston. This also means that the block has to be bored oversize too. All bearings have been replaced for new and obviously oversize.

I am also having the head "slightly flowed" with new valve stems fitted as well as the valve seats re-cut. Seeing as I am having the head flowed, I thought it best to have some nice shiny new vernier cam pulleys to set it all off! Along with a full set of new gaskets, of course.
This is the crank before the re-grind


And after the work had been done...............looks brand new!


That's the engine side of it and I will post some pics as soon as I get the engine back from Clint.



The other problem I had with the car was that it was always wet in the driver's foot-well, even when the car hadn't moved. So I decided, while it was off the road I would investigate where it was coming from. Took all the interior out, including the sound deadening from the drivers foot-well. It wasn't easy to find, but eventually (well, hopefully pray found it coming from just under where the fuse box is. It's not actually coming from the fuse box itself, but where the two panels meet. I think the seal has perished and has started to rust........hence, cracks have appeared. It definately isn't a hole, so I dried it all off (with the Missus's hair dryer! ) and then used plenty of silicone sealer. It's a really bad place to try and repair it by welding.
While I was repairing the water leak on the drivers side, I had to remove the N/S inner wheel arch liner as I had had a "little" fire in the engine bay, before the engine went off to Clint's.
Wasn't too bad, if you can look at it like that. All I did was melt the inner wheel arch liner, steering rack boot n/s, some engine loom (all that's been sorted now) and the bottom of the wing.

After I removed the liner I had a good nosy under the inner wing and found a crack (no innuendos please!) with lots of rust.

Well, here are some photos of how I went about it.....................

This is the offending rust!


And here it has been treated to Kurust


I then waited for the Kurust to dry and then applied "weld thru" Zinc Primer


I made a templet fro cardboard and then transfered this to mild steel.
cardboard templet.


Mild steel.

the steel was slightly rusty, so I just painted it with Kurust and then cleaned the metal.

And here's the finished repair...............


After I had finished I sprayed all the inner wing in Crystal Blue paint. Not that you will see it, but at least I know it's been done.

I know it's not the best in the World, but it's a damn sight better than it was.



More to come...................





Scouse.

[PIG]

bufty boy now then m8,good repair there m8 well done for doing it buddy.will be nice when the engine gets put back in m8.when you getting it back gary?

[mk1matt]

You plated over the rust
I do that

[Scouse]

PIG,

Going to collect it at the end of the month, finished or not!


Matt,

it was in a really awkward place to cut out and repair properly, right under the battery tray. I suppose if I ever do a full resto, then I will cut it out and do the repair like it should be done. That's the only rust on the car, well, major anyway. Doesn't help when you have to do these repairs on the road outside your house




Scouse.

[Stu.C]

Doing something is better than doing nothing!

Glad to see the ball's rolling on this one again - and look at it like this; if it ever leaks into the footwell again later, you'll at least know where to look

[Scouse]

Just got a few pics off Clint! cheeRS Mate!











WOW!! I could look at them pistons all day!



Scouse.

[Broadmoor]

[quote=Scouse;1410195]Just got a few pics off Clint! cheeRS Mate!











WOW!! I could look at them pistons all day!
Quote

You prob will be looking at them all day /week / month

[Scouse]

Now Now!!!




Scouse.

[mk1matt]

Same make as my pistons scouse
And i quite often look at mine (and no i wasnt given them )

[Scouse]

Still not got my engine back, but did get a few more photos from Clint! (thanks again! )






















Scouse.

[4parajon]

Looks good Scouse, get some pics of the car up as I havent seen it yet??

[Scouse]

Looks good Scouse, get some pics of the car up as I havent seen it yet??

How d'you mean?



Scouse.

[4parajon]

How d'you mean?



Scouse.

What dya mean "How do I mean"
I
Want
To
See
Pictures/Photo's
Of
Your
Car

I can't put it any simpler than that can I

[Scouse]

Don't shout!!!



I thought you had seen it Will do!



This was before the engine "went".

Scouse.

[4parajon]

Looks nice mate, and no Ive never seen piccies of the car before, have you got anymore than the one.......or do I have to start begging???..........., christ its like pulling teeth this is

[PIG]

scouse is it sat on bricks there or have the wheels not been nicked in that one m8..when do you get the engine back then as pictures dont give it power

[Stu.C]

I thought you had seen it Will do!

Ooh nice ... is it an estate?

[4parajon]

Ooh nice ... is it an estate?

Think it might be in a "state" Stu

[david tait]

What spec / power are you going for mate ?

The car looks in nice condition.crystal blue is a weird colour though yours looks great on the multispokes

[Scouse]

PIG,

Still waiting from Clint, but hey, I'm getting used to that!


Jon,

Yep! It's in abit of a state at the moment...........no interior, roof lining (still looking for one) and needs the fromt N/S wing painted again, after my mis-hap!


Dave,

It's running stage one (was before the engine "went"). Full leather, S/S exhaust, Black Diamond discs...also got a brand new set waiting to be used. And a brand new set of wheels/ tyres, but not sure whether I'm keeping them.

The engine has been bored +50' and the crank has been reground +50' too. New pistons, shells, gaskets etc. The head has been gas flowed by Vulcan Eng. and I'm having a new set of verniers fitted.

As far as I know, it just needs the head putting back on the block, timed up and I can go and collect it.

I also have a new clutch plate, pressure plate and bearing. Not going to fit a paddle clutch as I will use it every day. While it's been off the road I bought a front strut brace and a cone filter. Also fitted a DVD TV.


And the wheels are TSW Imolas, they need a good clean and a bit of a refurb. And the colour is defo a Cossie colour. Apparently they only made about 250 2WD in that colour, so it's a bit of a rare colour.






Scouse.

[Stu.C]

We need more pictures Scouse

[Scouse]

Just thought I'd add that I'm off work for a week next week! and will start putting the interior back in...............in between cups of tea and taking the dog for a walk, that is!

*note to 4paraJon*

Will post the pics as and when I take them

Stu,

Will be taking plenty, Mate.....................calm down, calm down!




Scouse.
P.S. Jon, is that "space still available if my engine's not sorted?

[4parajon]

P.S. Jon, is that "space still available if my engine's not sorted?

Technically no but if your desperate I might be able to sort something out. Since we last spoke about it Ive inherited an ex XR Challenge track day fiesta and a trailer.

[Scouse]

Never mind, will have to try and get summit sorted and soon perhaps!



Scouse.

[Kieron]

Crystal Blue has to be my favourite 2wd colour. Trouble is it only comes with E platers that can sometimes be "abused" Will be nice when its back together Scouse

[dangerousdave]

And f i think kieron, pretty sure my bros is an f reg without the private plate, and yes its been ragged hard and the hardest is yet to come

[Kieron]

Very rare on an F I think, showroom models registered late IIRC??? Either way a cracking colour.

[dangerousdave]

Just done a data check its come back as 01 08 1988, and from what i can google that makes it bang on the date of the changeover so must be as you say

Shame its gonna get abused hard

[Scouse]

As you all may know, I picked up my engine from Clint on Wednesday. Long trip to Brands and the traffic was a nightmare, to say the least!

Anyway, the engine looks brill and very very clean

When I get all the info off Clint about the parts he's used I will post them up, but until then, here's a couple of pics of the "beast"







Scouse.

[Dave]

Nice one
I don't have a lot of spare time, so can only help in evenings really, but if you need a lift in with it give me a shout
(ps. I know bugger all about cossies )

[Scouse]

Dave,

Thanks for the offer! got to speak to James (bmwJames) 1st as he said I could borrow his engine hoist. Missus isn't too happy the engine's in the back room, but when are they ever happy?

Just happy it's here more than anything. I am moving the car to a lock-up about a mile from mine in the next week or so too. Tax is up at the end of the month. And what makes matters worse is that I still have a water leak some where under the drivers side bulkhead/ dash area!

So before I can even put the seats, carpet and rest of the trim in I will have to find it. But I have a cunning plan...............I bought some food colouring which I'm going to mix with water and pour it over the suspected area and maybe I can find the leak easier.




Scouse.

[351escort]

A good trick to find water leaks is to dust the area with talcum powder that way you will see the water run down it

[Kieron]

Looking good!

[Scouse]

Well,

I have since re-wired the engine bay loom. Bought one off here and all the burnt wires have been replaced too. Looks really good now, made up with it.

I took the wiring grommet from the passenger side bulkhead and put it into the drivers side as that grommet was split beyond repair by the "monkey" who fitted my alarm (*mental note* never use that firm again). It fits loads better and hopefully will have cured the water leak......only time will tell.

While I was sorting the wiring out and my trusty gas soldering iron was handy, I fitted my DVD player into the top vents. All wires soldered, taped and neatly routed behind the dash. And it all works great, I even wired it to the handbrake, so when the handbrake is off I lose the picture. Would be tempted to watch the TV whilst driving and my luck I'd get a "pull".















Scouse.

[4parajon]

Good work mate

Have you got all your engine bits now then or what, is it in yet etc etc???

[Scouse]

Just got back from the lock-up and have now fitted the carpet with door trim, dash trim with clocks etc and the drivers seat.

Replaced the steering rack boot as it got burnt in my little mishap

Started to put the bits on to the engine now, like the water pump, clutch and pulley.


If I work my nuts off and the weather stays fine I could have the engine close to being in by the weekend.




Scouse.

[4parajon]

Nice one, glad its finally coming together for you

[dangerousdave]

Scouse stop messing about with the fancy bling and get the engine in mate

Is this coming to classic ford??

[Scouse]

All the interior is in now..............apart from the back seat, but that's a 2 min job. Now wired in the turbo timer properly this time! and all electrics are working fine, well the ones I can test without the engine running. Even the ABS light goes out, which is quite a rare thing on Cossies


What's left to do?

New brake discs
Fit the engine,
Strut brace...............have to cut the heat shield so it can fit OK.
All engine bay bits............radiator, intercooler, fans, etc.


And then..............A TEST RUN!!!


Dave,

Trying my best to make it





Scouse.

[tom burgess]

Good going scousehopefully it will be done for CF