Sierra RS Cosworth 3Door

My own personal project car, purchased back in 2010 an unfinished project missing a lot of parts , and the parts I had appeared to be a mix of 3door Cosworth ,xr4i and sahhire Cosworth

The Cosworth seems to have spent a lot of its life off the road so the shell was in very good condition the only issues being a damaged rear panel and front bumper. Dismantled and the external panels stripped back to bare metal the shell was in good condition with little to no filler and no dodgy repairs so  a genuine Ford rear panel purchased the shell was soon prepped and into primer.

The next decision was the colour- Effeti orange mica (bearing in mind this was 2010 and everyone wanted something a little different )

Various parts for the interior had to be sourced due to either being missing or damaged.

 

The engine was in the car but a lot of the ancilliaries were missing; the main part being the ECU and loom, After dismantling the engine and finding some scoring a rebuild was needed, also a rebore, regrind and replacing the pistons pumps etc. Whilst rebuilding  a cometic gasket some green injectors, 3 bar map sensor and -31 actuator made it on to the car along with a 4×4 intercooler.

The usual coloured samco hoses and stainless parts (all the rage back in 2010)found their way into the build along with a few new genuine Ford parts.

In keeping with the rest of the build the underside and the suspension was also treated to repainting along with all new brakes, shocks, poly bushes etc.

The original Cosworth’s interior had unfortunatly not been treated too well with the usual Recaro wear on the bolsters plus cigarette burns etc, the door cards had also suffered a hard life with various splits and holes drilled in them, As good replacement seats cost an arm and a leg the decision to retrim was the best option plus helps to add a bit of individualism to the car to match the exterior. The seats were re-upholstered in alcantara by my very talented better half, the door cards were repaired and also recoverd with the same material to match the seats.

A genuine RS 500 lower rear spoiler and bumper grills were sourced.

A set of replica RS 500 splitters were added with a view to swap to the real items when they become available.

 

Unfortunatley the car never quite made it onto the road despite only needing an Mot, tune and road tax. With the arrival of my daughter the Cossie entered storage where it stayed tucked away for 4 years.

The car finally came out of storage but being left for years has led to running issues and a roof collapse of the storage area has left the Cosworth in need of a little work .

Due to damage

A  few calls to my contacts and a rare genuine new roof skin has been sourced to replace the damaged one.

With the new roof skin in place the decision to strip off the remaining parts was made so the Cosworth could have the restoration it deserved

Last time due to time and that I was using somone else’s workshop the inside and the underside were left ,as they looked ok covered in a reasonably fresh coat of Shultz

Off for blasting

Once back from blasting it was clear the underside as rust free as I thought, not rotten but the corrosion had crept into the usual places

The usual sierra issue where people jack up the  car thinking this is a jacking point rather than a floor reinforcer

A section of the sill also needed replacement