My 205 4X4 Cosworth

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Hi all,

I will try and add in a bit of build thread but some pics of the rebuild so far: It is being mapped in the next 10 days with a new Borg Warner twin scroll Turbo, I am expecting 400 to 440 bhp but will soon go to 520.

Edited by Caddyshack on Friday 7th February 10:38

Edited by Caddyshack on Friday 7th February 10:41

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Wow, thanks for the nice comments, I wasn't sure if I would get nice comments or not.

The Steelie is slowly being restored, It has the full green carpets etc and even has the very rare green seatbelts which was normally only available in France (I think)

Re the Cossie Pug: I will shortly get some pics up of the stack dash and fully flocked interior and retrimmed Cossie seats

This was originally a 1.1 van before the conversion, it was on the front page of Max power in the 90s

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dragonheart said:

Agree with all of the above comments, that truly is one epic car, love everything about it apart from one thing, the exhaust. IMHO the twin pipes exiting through the bumper kind of cheapen the look of what is a stunning creation.

Funny you should say that! They are going, they look too 90's Barry boy plus the new supra diff is a bit wider where the pipes separate. I am going to have them remade with an extra box after the diff and then one exit as per the real T16 would have.


Hi Dubmonkey!

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eybic said:

I've linked to it on the PH Facebook so you should get some more attention

Thank You.

I am actually quite overwhelmed by the support, I have worked virtually every Saturday and Sunday on this car from strip down to repaint and rebuild for a year now....lots more to do though.

I spoke to Reyland today and I think I am going over to their Skyline gearbox to handle the torque which I think will be close to 500lbft and he can get the centre diff to control from full RWD to 50/50 front to rear which should be good for track days to get the power more rearward. I will have his AP conversion on the brakes too.

I have driven it hard at 360bhp and it is very fast but quite tame and puts all the power down in the wet, I think it will spin up soon though.

Mark Shead at MA Developments is going to map it.

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SteveRST said:

Really like this. Would be nice to see some up the build pics with commentary. Do you have a pic of it when it was a 90's Max Power cover car then too?
Awesome work.

Yes, I have the original magazine and will post it up along with some of the "before" pics and part way through. For example the car had 100 liters of high build primer to take the ripples out of the kit and the normal pug panels.


Mark Shead is the absolute guru of Cossie mapping and such a nice bloke, I asked around and his name kept coming up with comments like "if Mark says 500 bhp then that is exactly what it will have" the Cossie world is a bit like the SAS it seems everyone you meet is ex SAS and every Cossie is 400 bhp plus.

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Thanks you lot...it is Vanny Magnet, yes! I have stripped the whole car and cannot find the magnet though!

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DiscoStu said:

Cool this is Muppets old car. Haven't seen it for a while. It used to be in the Newport area, South Wales. Seen it many times in the flesh, very quick

Here is his old build thread on passionford:

http://passionford.com/forum/restorations-rebuilds...

Great car good luck with it.

Yes, I have added to Muppets thread, the car went from him to a trader who had it up with a 6r4 and sold them after losing his licence, Lance Thorn then bought the car and ran it for about 10 yrs, it was then bought and had a freshen up and the compomotives were added, Matt then bought the car and after 5-7 yrs in his care I bought it via pistonheads, it was in the track day section and I was looking for parts for the steel grey 205, turns out it was about 5 miles from my house so I went to see it and bought it.

I am so pleased with all the kind comments on here, really makes the bashed knuckles and empty bank account worth it. I will put up some build pics soon.

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Yes, the wheels are compomotives, th I think. 16 inch.

I have been thinking of the ambers all round as think it will be nicer, I have some morrettes to try too, using one as a cold air feed to the turbo.

The car was built by DJM at a reputed cost of £30k plus in the 90s, they built Colin McRaes rally escort. Underneath it just looks like a Sierra Saphire and is really nicely done. It has done 36000 miles from new and is super clean, I did not find a single piece of rust anywhere during the full strip down.

I have repainted underneath too

Edited by Caddyshack on Saturday 15th February 19:05

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Yes, I do have a set of morette but I don't think I really like them but the cold air feed may be needed, not too sure.

H20 COS looks nice on them but have always preferred the std 205 lights

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Storer said:

Lovely looking car. Purposeful and well proportioned and not "chaved" from any angle.

For someone who hasn't seen it before can you explain if the car is a 205 body welded to a Cosworth (Sierra or Escort) floor pan or if the Cosworth components are mated to the 205 body. Is it registered as a Ford or Peugeot is my question I suppose?


Paul

Hi, it is a 205 body with Sierra tranny tunnel grafted in and the the Sierra subframes have been welded in to suit, all the suspension, brakes, driveshafts and engine mounts / cradles are all as Ford intended. It is regd as a Pug.

It drives like any production car really, just fast.


Ninjacost.....many thanks, hopefully it will stand side by side with H20 when it is finished.

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My Rear Supra diff has gone off to Bara for a refresh, repaint, LSD setup with seals and bearings, it will then go on to the cosworth conversion kit from MK Motorsport which should stop the rear diff popping.

The car should be back from mapping and new engine loom on vipec with the Borg Warner twin scroll in 2 weeks, I will post up the dyno plot.

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I think you are pretty close on the weigh, I will have it corner weighted soon but expect around 1100 wish when you take in to account the running gear, bodykit and cage plus the added turbo and intercooler etc...so it could be near 1200. I will work out the power to Weight once I have the dyno plots and the car back to weigh it.

There is a fair bit of trim stripped out plus the old rear beams are pretty heavy but then I have an extra diff to consider.

We already know what is needed for 520 BHP but I need the new gearbox in first to handle the power. My supra diff is all built up and running the MK conversion to fit the Cassie. I am going for an oppliger close ratio long box as they can handle 700 BHP and the ratios are much closer so the top end will drop to 150 mph at 7200 but the engine will be in the sweet spot more of the time so acceleration should be vivid.

A similar spec car was quicker than the owners V10 Limbo but he had a much more laggy turbo and about 30 BHP less.

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I still own it. It has been away for a long time having a Wrc cage put in along with a rear cradle and much better suspension.

I will upload the old pics but here are some of the work being done









More to come

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Above is the new turrets with WRC billet strut tops, these have remote reservoir black art design dampers (same at front)



Cage going in



Massive spec stroker engine, it made over 700 bhp when mapped, it is now being de tuned with smaller turbo.



Wrc cradle

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Basic spec:

Quaife front diff 3.9 ratio, supra rear diff 3.9 with weir kit, bad dampers, Wrc bladed adjustable anti roll bars front and rear, Wrc front and rear cradle with Wrc hubs, Wrc spec cage, close ratio 4x4 box built for 700 bhp.

Doors and boot are carbon Kevlar, bonnet is full carbon fibre and the wings are fibre glass and Kevlar.

The cage, cradle, connecting suspension rods and front suspension cradle are all in super strong but super light t45 steel. Hubs are billet alloy so we have saved a load of weight off a normal 205, plus the interior is stripped with just light buckets. The doors alone were over 25 kilos lighter (for the pair), bonnet is around 8 lighter and boot is 12 kilos lighter. The majority of the bolts on the car are titanium (every external bolt on the engine is titanium).

The engine is chassis mounted as per a Wrc escort Cossie so the front suspension can drop out on 4 bolts plus the top mounts and leaving the engine in situ.

It has a huge spec r intercooler now as these have proven to be the best as used on Rod Tarrys 200+ mph Sierra (same mapper as me)

The close ratio box has uprated viscous coupling for better split on the centre diff.

Edited by Caddyshack on Wednesday 29th January 21:15

Edited by Caddyshack on Wednesday 29th January 21:18

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On the 500 bhp engine it was able to spin up all 4 wheels rolling along in 2nd then flooring it, it is now over 200 kg lighter and will probably end up 130 bhp more and getting on 530 ftlb too.

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It has these hubs front and rear with huge wheel bearings and big discs all round


Front adjustable Track control arms, it has WRC style Adjustable compression struts too



Here it has the previous BTCC style 6 degree beam, before I stripped it out for the new rebuild. It has spent more time on my ramps than off it, sadly.

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Thanks Guys.

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I am pleased with all the lovely comments.

I repainted it the original red colour due to it being well known in max power. I have toyed with white and make an homage to the full rally colours. At the moment it is staying red.

It is still stuck at the fabricators and I am collecting in May 2020.

There is still a lot of work to go...electric adjustable corsa power steering running quaife manual rack, Wrc pedal box, Wrc sill stands, new fuel tank, new exhaust tucked up in the raised floor, seat mounts.....