FREE Ford Cougar Track Project Build Thread
Discussion
Have decided not to go down the coilover route, due to what people have to say about them (cougar owners) and the cost (£1300). Luckily I have asked father christmas nicely, and he should be brining a set of sport shocks and springs. 
Have had the welding done, and put larger brakes on the front + braided hoses. Will get some pics up when time allows.
Plan is to take it to keevil on the 20th. Cant wait!
Have had the welding done, and put larger brakes on the front + braided hoses. Will get some pics up when time allows.
Plan is to take it to keevil on the 20th. Cant wait!
Sorry for the lack of updates.
I have had the car on a track, and it was great fun. I think I may have the bug! The car went well untill the last 1/2 hour when it sheered a wheel stud - such is life.
Since then, father christmas delivered a new set of springs, and I got hold of some new shocks for the front. I may get some for the back aswell if I can find the money. I only got round to starting work on the car today, so thought I would share a few pics.
Car stripped, with upgraded brakes and braided lines, while removing struts;
Dismantled the struts. The top spring holder was rather rusty, so spent a while with the angle grinder and a cup brush;
Then a coat of hammerite satin black;
Then I removed all the clips and bits from the wheel-arch. I then sanded all the little bits of rust out, and applied a coat of hamerite 'stonechip' but the camera battery was dead, so didn't get any pics. Will get some next time I go.
There is also a bit of surface rust on the sills, so had a go at that as well. I want to keep the car for a while, so it's worth the time spent.
Now just have to wait for the keevil dates to be put up (and put the car back together!)
I have had the car on a track, and it was great fun. I think I may have the bug! The car went well untill the last 1/2 hour when it sheered a wheel stud - such is life.
Since then, father christmas delivered a new set of springs, and I got hold of some new shocks for the front. I may get some for the back aswell if I can find the money. I only got round to starting work on the car today, so thought I would share a few pics.
Car stripped, with upgraded brakes and braided lines, while removing struts;
Dismantled the struts. The top spring holder was rather rusty, so spent a while with the angle grinder and a cup brush;
Then a coat of hammerite satin black;
Then I removed all the clips and bits from the wheel-arch. I then sanded all the little bits of rust out, and applied a coat of hamerite 'stonechip' but the camera battery was dead, so didn't get any pics. Will get some next time I go.
There is also a bit of surface rust on the sills, so had a go at that as well. I want to keep the car for a while, so it's worth the time spent.
Now just have to wait for the keevil dates to be put up (and put the car back together!)
So... I've been rather bad at updating this thread, but having just seen another thread where the same thing seems to have happened, it reminded me that I ought to post an update.
I have done many track days with it - and it has been great fun! For those that use Motorsport Events, you may well have seen it out.
A fair amount of work has happened since I last updated the thread and I will attempt to give a quick rundown and some pics over the next few days.
I have done many track days with it - and it has been great fun! For those that use Motorsport Events, you may well have seen it out.
A fair amount of work has happened since I last updated the thread and I will attempt to give a quick rundown and some pics over the next few days.
As promised, better late than never, I'll give an update.
I will try to give an overview of whats happened up to date, but I did get rather bad at taking photos so they may get a bit sketchy at times.
Anyway;
Its a common issue with the Cougar / Mondeao for the rear subframe to rust through. As they are rather hard to find, I thought it would be sensible to sort sooner rather than later.
Exhaust removed;
|http://thumbsnap.com/sMsMWmZ3[/url]
Subframe out;
Most important mod to date added;
Front wheel arches were a little rusty so ground out the rust;
Treated them and gave a quick blow-over with white stonechip paint;
I will try to give an overview of whats happened up to date, but I did get rather bad at taking photos so they may get a bit sketchy at times.
Anyway;
Its a common issue with the Cougar / Mondeao for the rear subframe to rust through. As they are rather hard to find, I thought it would be sensible to sort sooner rather than later.
Exhaust removed;
|http://thumbsnap.com/sMsMWmZ3[/url]Subframe out;
Most important mod to date added;
Front wheel arches were a little rusty so ground out the rust;
Treated them and gave a quick blow-over with white stonechip paint;
Managed to acquire a rear strut brace so added that;
Subframe was rusty but solid;
Having had a quick go with an angle grinder and wire brush I decided that I would never do a good job and so thought sandblasting would be a sensible idea. I stripped the 'frame down and found a local blaster who did it all for £20 (form memory!).
Luckily no problems with it and it was all really solid. Decided whilst it was apart it made sense to change the bushes. Not something I'd tried before (and not a job I would rush to do again). A lot of swearing ensued but got there in the end.
Having read a bit on-line, I decided that POR15 seemed the best paint to use, so ordered myself a a few tins at what seemed like vast expense
It turns out that when they say it doesn't come off skin; it really doesn't! Looked like new when done though.
I also de-rusted all bolts using rust remover, treated them and painted them to stop further corrosion.
Subframe was rusty but solid;
Having had a quick go with an angle grinder and wire brush I decided that I would never do a good job and so thought sandblasting would be a sensible idea. I stripped the 'frame down and found a local blaster who did it all for £20 (form memory!).
Luckily no problems with it and it was all really solid. Decided whilst it was apart it made sense to change the bushes. Not something I'd tried before (and not a job I would rush to do again). A lot of swearing ensued but got there in the end.
Having read a bit on-line, I decided that POR15 seemed the best paint to use, so ordered myself a a few tins at what seemed like vast expense
It turns out that when they say it doesn't come off skin; it really doesn't! Looked like new when done though.
I also de-rusted all bolts using rust remover, treated them and painted them to stop further corrosion.
One of the straps for fuel tank was looking rather worse for wear, so the tank was removed. Having got a quote from Ford for a new one, I recovered from the shock and set about fabricating one myself.
Using some sheet aluminium and the steel ends I recovered from the old strap I managed to get something which seemed half decent. I decided that if I had cocked up majorly, the sub frame would stop it going too far
It hasn't broken yet so it turned out all right
At the same time I ground out any rust, treated and repainted with silver hammerite. A pain to do on your back. It's amazing how much paint you can cover yourself in!
I then set about assembling the new suspension. It seemed silly to put new springs on old dampers so I got a new set of those from EBay. The cost of coilovers was prohibitive, and not something I could justify, but this should be better than standard 100k+ suspension units.
No photos, but I assume they went back in OK. The car was slightly lower at the front and about standard at the rear. I would like it to be a bit lower ideally. For all that, it seems to handle OK on the track considering the size.
That's all for now. Will give some more updates tomorrow!
Using some sheet aluminium and the steel ends I recovered from the old strap I managed to get something which seemed half decent. I decided that if I had cocked up majorly, the sub frame would stop it going too far
It hasn't broken yet so it turned out all right
At the same time I ground out any rust, treated and repainted with silver hammerite. A pain to do on your back. It's amazing how much paint you can cover yourself in!
I then set about assembling the new suspension. It seemed silly to put new springs on old dampers so I got a new set of those from EBay. The cost of coilovers was prohibitive, and not something I could justify, but this should be better than standard 100k+ suspension units.
No photos, but I assume they went back in OK. The car was slightly lower at the front and about standard at the rear. I would like it to be a bit lower ideally. For all that, it seems to handle OK on the track considering the size.
That's all for now. Will give some more updates tomorrow!
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