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Thread: DW's Sapphire Cosworth race car

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    Pole Position Decade Plus User david_white's Avatar

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    DW's Sapphire Cosworth race car

    As most of you know my 3 door shell is a little worse for wear following a little brush with the armco at Brands last year. In order to get back on track ASAP I have aquired a 'solid' genuine sapphire cosworth shell which will have fitted the running gear and rather splendid engine from the old car.
    Why Sapphire? Well the shells are cheaper, panels are a lot cheaper and easier to come by and it will be lighter and stiffer than the 3 door, even more so once fitted with a full weld in cage (3 door had older 'bolt in').

    Heres some pics of it once I'd got it home and mocked up the lights etc.







    The plan is lighter and stronger. The car will get respray, full cage, proper seat mounts, new perspex and new pedal box amongst other things..

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    Re: DW's Sapphire Cosworth race car

    Rest of interior trim removed, belts etc.. and some very dodgy sections of floor where water has sat in shell!






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    Re: DW's Sapphire Cosworth race car

    Soundproofing matting stuff removed!!






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    Re: DW's Sapphire Cosworth race car

    ..and after a clean up with thinners and more sound deadening removed,









    All in all over 10kg of the stuff removed from the floors, and still a little more to do.

    Have also removed boot hinges, battery tray and any unwanted brackets in the name of weight saving

    Removal of sunroof and all floor repairs will be done soon prior to a cage going in, then it should be almost ready for the paintshop.

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    Re: DW's Sapphire Cosworth race car

    Looking good so far...is it a factory sunroof...when i took mine out i took thr inner skin as well massive saving of weight...mark

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    Re: DW's Sapphire Cosworth race car

    Looking good. I hate removing that sound deadening!

    Best hurry up though the season starts in a few weeks

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    Re: DW's Sapphire Cosworth race car

    Looks like your rear turrets have had strengthening measures for coil-over suspension.

    What colour are you going for?

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    Re: DW's Sapphire Cosworth race car

    Oh and if your going to chop up your rear bumper like you did with your 2 door I am looking for a good one and have one here to chop up?

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    Pole Position Decade Plus User david_white's Avatar

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by mk22door View Post
    Oh and if your going to chop up your rear bumper like you did with your 2 door I am looking for a good one and have one here to chop up?
    Havent had a real good look at the bumper yet, I'll probably run a fibreglass / kevlar front and std rear with inner strengthening taken out, similar as you say to my old one. I did wonder about the turret strengtheners but I assumed it was a std saph cossie fitment, sound deadening was over the top of it too ..
    Have a couple of ideas on colours but will have a chat wih the painter first. Really like the magenta but if we're doing loads of mods to the car dont want it to look like a std car with numbers stuck on!

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by madragon199 View Post
    Looking good so far...is it a factory sunroof...when i took mine out i took thr inner skin as well massive saving of weight...mark
    Yes std sunroof with the massive inner skin. Was considering using this panel for a floor repair once cut out as it looks good. Will be another chunk of weight out once its gone though.

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    Pole Position Decade Plus User david_white's Avatar

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by Nelly View Post
    Looking good. I hate removing that sound deadening!

    Best hurry up though the season starts in a few weeks
    Sound deadening came off quite nicely considering, although my heat gun was blowing bits of itself and flames out by the end!

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    Re: DW's Sapphire Cosworth race car

    Looking good Dave but you are going to have to pull your finger out to be ready for the 12 th

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by Toymex View Post
    Looking good Dave but you are going to have to pull your finger out to be ready for the 12 th
    Unfortunately I'm 3 months behind schedule as our house move took forever meaning nowhere to put the new car or get it started. Got a bit of momentum back though so progress should be steady now.
    How about you, little Nova ready?

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    Re: DW's Sapphire Cosworth race car

    Took the nova for a shakedown yesterday ,nothing fell off but the handling left a bit to be desired and the pedal box needs some learning as the pedals are so close ,braking and accelerating at the same time is not the best ,but all things being even I will be at the first meeting

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    Re: DW's Sapphire Cosworth race car

    After the nasty job of stripping the floors inside the car I thought I would start the even nastier job of removing the underseal, waxoil or whatever the hell it is covering the bottom of the car.





    Engine bay pretty much stripped down and battery tray removed



    Hopefully get more underseal off tomorrow, and start to work towards the rear of the car, which has plenty of 'issues' to sort out, like why virtually every captive nut has been broken! (Someone attacked everything with an impact gun methinks)

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    Re: DW's Sapphire Cosworth race car

    Looks a good solid shell , great start for the build!! Look forward too seeing the stages!! Best of luck with it

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by gizmo 5 View Post
    Looks a good solid shell , great start for the build!! Look forward too seeing the stages!! Best of luck with it
    Thanks but back half is not so solid. Got a few holes and a very bad arch to sort but I figure theres no point starting the repairs until all of the underseal is gone and we can see what we are dealing with.

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by david_white View Post
    Thanks but back half is not so solid. Got a few holes and a very bad arch to sort but I figure theres no point starting the repairs until all of the underseal is gone and we can see what we are dealing with.
    Still not to bad for a Sierra !! Your right to clean down the whole shell at least you'l know there is no nasty surprises hiding anywhere then!!! Look forward to see'n the build!!

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    Re: DW's Sapphire Cosworth race car

    Before and after...







    Boot floor will be made from a flat sheet of steel welded in to conform with the regs, will also need bead rolling or similar to add a bit of strength and prevent vibration.
    A firewall will also be made in at the same time as the tank will probably sit inside the boot this time rather than under it.

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    Re: DW's Sapphire Cosworth race car

    Looking good mate, the underseal on saphs and the escos is a right bitch to remove 3 doors aint as bad but when i done my escos it was a right pain... Ill keep an eye on your build have a soft spot for track saphs

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    Pole Position Decade Plus User david_white's Avatar

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by R5COS View Post
    Looking good mate, the underseal on saphs and the escos is a right bitch to remove 3 doors aint as bad but when i done my escos it was a right pain... Ill keep an eye on your build have a soft spot for track saphs
    Cheers Bud, yeah the underseal is well stuck on there in places. The tunnel and curved panels seamed to strip off ok but the flatter floor sections are not looking like they will be easy. At least at the back there is a couple of square feet less steel to strip now!!

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by david_white View Post
    Cheers Bud, yeah the underseal is well stuck on there in places. The tunnel and curved panels seamed to strip off ok but the flatter floor sections are not looking like they will be easy. At least at the back there is a couple of square feet less steel to strip now!!
    Nice cold day and a hammer and bolster so it cracks off in chunks

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by Nelly View Post
    Nice cold day and a hammer and bolster so it cracks off in chunks
    Tried that, came off in very tiny pieces. Most of it scrapes off with a little heat, followed by some thinners or petrol to clean it up, but laying under the car in the cold wears a little thin after a couple of hours!! Would be a piece of cake if the car was on its side or on a spit.

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by Nelly View Post
    Nice cold day and a hammer and bolster so it cracks off in chunks
    I have used the blow torch method in the past with a wallpaper scrapper had good results but be warned its very messy and keep the door open to let the smoke out..

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by R5COS View Post
    I have used the blow torch method in the past with a wallpaper scrapper had good results but be warned its very messy and keep the door open to let the smoke out..
    I have used a heat gun until it was basically blowing molten bits of itself at the car lol. Might try a blow torch if it gets particularly tricky..

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    Re: DW's Sapphire Cosworth race car

    Todays delivery from plastics 4 performance. Shaped rear screen, smoke tint and sliders on fronts



    Rear will be bonded in and they should look OE apart from sliders with a bit of luck.

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by david_white View Post
    I have used a heat gun until it was basically blowing molten bits of itself at the car lol. Might try a blow torch if it gets particularly tricky..
    Blow tourch will work well, but remember what u have in your hand, u dont want it going very wrong very quick

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    Re: DW's Sapphire Cosworth race car

    Quote Originally Posted by R5COS View Post
    Blow tourch will work well, but remember what u have in your hand, u dont want it going very wrong very quick
    Exactly, better be patient and keep on the way i am I think. At least this way i can clean it up with thinners as I go too as its always motivating to see a nice clean panel emerging

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    Re: DW's Sapphire Cosworth race car

    Looks a good shell to start with, no doubt it will be a cracker once it's done if it's anything like your old 3dr,

    My old 3 dr Cos lost 23 kilos when I replaced the roof and sunroof with a carbon roof!

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    Re: DW's Sapphire Cosworth race car

    Update time; a new T45 custom cages roll cage has arrived ready to fit at Graham Bahrs, Penguin motors.
    I was still not particularly happy with the magenta shell as further work underneath had uncovered a few more areas where work was required, and even with repairs it wouldnt have looked pretty under there. The plan was always to get the car up to Graham this week and at the last minute Frank and Gemma (Frostracing) offered for sale their near mint white sapphire shell that Gemma was going to build up as a std road car. I jumped at the chance and by buying this shell have saved a lot of time, work and money in not having extensive repairs carried out.

    The suspension off of the 3 door all got stripped, cleaned and repainted ready to go on the lovely new shell, along with the new Graham Hathaway beam;








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    Re: DW's Sapphire Cosworth race car

    Andy Pipe, myself and Frank 'no kettle' Frostick fitted up all of the suspension and steering in an hour, which was easy on Franks ramp using his transmission jack. Again big thanks to Frank for his help and Gemma for letting me have the shell.



    After a quick roadtrip up to Ely the car is now at Grahams new unit ready for the new cage, a firewall and a couple of other little jobs.


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    Re: DW's Sapphire Cosworth race car

    it doesnt look much but ive done a bit, removed the last of wiring and heater box. cut the screens out intact, the fronts heated and going back in the rear wont so if you want a rear sierra screen pm dave.

    ive also got rid of all the interior sound deadening pads, which i did on the hottest day of the year so far, it really wasnt the day to be using a hot air gun and scraping hard at the same time





    also removed the sunroof cassette, looks like a bit of sanding and worm poison needed on the inside of the roof

    Last edited by Graham; 19-07-2014 at 22:26.

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    Re: DW's Sapphire Cosworth race car

    Thanks Graham, awesome work. Might not look much but I know how long all those jobs take, especially the sound deadening! Look forward to the updates!!!

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    Re: DW's Sapphire Cosworth race car

    Missed this so far.

    Will be nice to see it progress!

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    Re: DW's Sapphire Cosworth race car

    a bit more progress.

    Click image for larger version Name:	dave saff.jpg Views:	588 Size:	122.0 KB ID:	70897

    a quick run over with a wire brush in the angle grinder followed with a wipe over from an old towel with some petrol/diesel mix took away most of the residule black gunk from the sound deadening pads



    someone had done a nasty hydraulic clutch conversion to the bulkhead, so i welded the plate on properly and welded up the holes in it. the battery tray has now gone, and the dark patch top left on the inner wing was a localised grotty bit where two panels meet, as it was fairly narrow i simply ground the grott out and welded it up

    from the inside
    daves going to fit a floor mounted pedal box so the other holes will be welded up later, im leaving them for now as they may make usufull access points for cage welding


    front footwell, the bit with the slotted holes will need plating over, you might notice a hole cut in the floor, i need a hole to drop the cage down to weld the top of it later on, but that bit was grotty, so i just cut a bigger hole and will make it a nice neat patch later.



    cage main hoop sitting in place, its not attached yet ive just worked out where it goes and trimmed it to fit the footplates, one things clear this cage seems to fit better than some from the manufacturer, but no way will i end up not having to trim some tubes




    main hoop another angle, with another hole to drop it through the floor, plate at bottom of B pillar is nothing to do with rust, it will be an attachment point for the door bar

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    Re: DW's Sapphire Cosworth race car

    Coming along rather nicely Graham. Will that cross bar on the main hoop tie in with the tunnel in some form? Obviously that will come last once the cage is up in its final position. Front bulkhead looks a lot neater now

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    Re: DW's Sapphire Cosworth race car

    No the main hoop x bar doesn't tie in to the tunnel, it should sit much higher where the top door bar and lower rear brace meet main hoop. Right now It's only in there to spread main hoop legs apart, it's a fraction too long and will need jacking into place

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    Re: DW's Sapphire Cosworth race car

    It's not obvious from the pics but I've also removed loads of little brackets, very time consuming but worth it's as weight wise it all adds up, and although looking good from the outside invariably there's rust forming behind them

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    Re: DW's Sapphire Cosworth race car



    a few more holes filled, again butt joined and seam welded, pop rivets and alloy plates would be a zillion times quicker. got rid of the screen bonding from the front screen surround and treated some scabby bits



    slots in the foot wells welded over



    hard to see but a couple of the many holes in the rear bulkhead welded, ive turned the shock bolt round and given it a captive nut, once everything is in, access to rear shock mount from the front side of the car will be very restricted, captive nut makes it an easy one handed job to unbolt the shock
    Last edited by Graham; 04-08-2014 at 08:50.

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  46. #40
    Pole Position Decade Plus User david_white's Avatar

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    Re: DW's Sapphire Cosworth race car

    My 3 door had captive nuts on the towers like that, as you say it pays to make jobs much simpler in the future. Been working on stuff lately where you wish to god someone had had a little foresight to imagine working on it once fully built up.
    Its all those little touches that will make it a joy to work on later on, rather than cursing with bloody knuckles lol!

    Sierra cosworth turbo race car
    QMN saloon car championship

    RETRO Motorsport

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