My 205 4X4 Cosworth

[s m]

Augustus Windsock said:

Fastdruid said:

Augustus Windsock said:

Not sure if anyone on here remembers, or even perhaps knows, but waaaay back a firm at Boughton (Notts) built the first car with Sapphire 4x4 running gear. I believe they are or were (?) DJMotorsport
It was built into a Ford Ka with wonderfully bloated wheel arches and you could actually see the diff under the rear when behind it.

That's is impressive....but ugly, it looks hideous. The 205 otoh is
https://www.djm-motorsport.co.uk/Ford_KA_Project.h...

If you're talking Cosworth conversions I very much prefer the Puma one. https://www.projectpuma.com/viewtopic.php?t=28350

Can’t say I’ve seen that post before about the Ka but he first one was built without a cage in it
The wheels were good coloured (speedlines?) and it was a flat grey colour
One owner lived on Clilpstone Road West in Mansfield if any readers remember it or know if it’s still about
As an aside, I was wondering what the insurance would be on a modified 205 like this?
I would ask the OP but that’s a bit rude. And private !

There was also Richie’s Ka featured on Speedhunters






http://www.speedhunters.com/2012/08/the-ka-coswort...

[Caddyshack]

Olivera said:

Curious, why didn't you just start with a Ford Cosworth of some kind, given that's the basis of the floorpan and running gear?

I love 205’s, always wanted a wide body 205 with cossie running gear.

When I bought it the floor pan was in along with running gear and engine.

The only Cossie I would want would be an Escos and even then I would want the big engine, decent gearbox and rear end so makes no difference, a Wrc spec escort to this spec would be £60k to £100k.

[Caddyshack]

The KA is nicely done, oddly enough I believe the KA is pretty much the same wheel base as the escort Cos.

[s m]

Caddyshack said:

The KA is nicely done, oddly enough I believe the KA is pretty much the same wheel base as the escort Cos.

I do like the 205s.....but I think if I had loads of cash to do something similar I’d have a 309 built up like this with the YB in



I liked my 309 Gti

[Caddyshack]

Thanks PH for the Readers Car of the week..it means a lot to me!

That 309 Goodwood is nice, there cannot be many left now.

[GVK]

grumpy52 said:

I have a dim memory of something very similar in the British rally championship back in the 90s . It was a bit of a gaint killer and on certain events it was untouchable.

That was a 306, Andy Burton's.

[okenemem]

amazing car

[BenLowden]

Caddyshack said:

Thanks PH for the Readers Car of the week..it means a lot to me!

That 309 Goodwood is nice, there cannot be many left now.

You're welcome! Although Jack was responsible. You have a PM from me about something else we'd like to discuss

[Caddyshack]

BenLowden said:

Caddyshack said:

Thanks PH for the Readers Car of the week..it means a lot to me!

That 309 Goodwood is nice, there cannot be many left now.

You're welcome! Although Jack was responsible. You have a PM from me about something else we'd like to discuss

Hi Ben,

I cannot find the pm so I have sent you a message with all contact details.


Editted to add: Got it now...YES PLEASE!

Edited by Caddyshack on Tuesday 3rd March 15:29

[Caddyshack]

A few updates of the underside. My actual gearbox is slightly longer than the mock up as it has a large spacer to allow for the bigger gears.

The underside will have a thin seam seal, then a light stone chip then body colour. I will wax oil all the cavities.

There is a lot of trimming still to be done and provision for the Wrc still stands and the chassis rails will be matched to the floor.









As you can see the ends / joins will all be tig welded together.

[GTRene]

wow, what a work, great stuf.

[F1natic]

Caddyshack said:

All 4 previous owners have been in touch and 2 lost their licences in it.

I think that is almost a certainty - you are going to have to have so much restraint to keep to the legal limits. What a legendary beast you have, very impressive shoehorning.

Caddyshack said:

A few updates of the underside.

Looks like it is rolled onto it's side? I really like that idea, great access, how are you supporting it?

[Caddyshack]

F1natic said:

Caddyshack said:

All 4 previous owners have been in touch and 2 lost their licences in it.

I think that is almost a certainty - you are going to have to have so much restraint to keep to the legal limits. What a legendary beast you have, very impressive shoehorning.

Caddyshack said:

A few updates of the underside.

Looks like it is rolled onto it's side? I really like that idea, great access, how are you supporting it?

Thanks.

It is on a rotisserie spit so that it can be welded at any angle. Seeing it upside down is weird

When I had the skyline box in it I altered the tunnel from underneath on my ramps, never again as blobs of weld dropped on my leg and set fire to my trousers and me.

[Caddyshack]

This thread is going to slowly document the rebuilding of my 205 4x4. Here is the car when it was last running.





It was the old Max Power cover car, built in 1990 to take a Cossie engine and 4x4 running gear:



When I bought the car it was still very max power and a bit tired. It was running 330hp but was laggy. I sent it off to Mark Shead who fitted a new Borg Warner efr turbo and Vipec engine management. It made 470hp and 500ftlb or torque which promptly destroyed the 4x4 gearbox within 250 miles.

I then fitted a 700hp rated Oppliger semi straight cut close ratio "long box" this is essentially the standard 4x4 casing with a longer spacer to allow room for bigger gears. It is not that noisey and the lower final drive reduced the top speed gearing from over 180mph to about 160 mph.

I then fitted a Quaife front diff with thicker case, strengthening plate and supports. The rear is a Supra LSD with weir kit. It was running a 6 degree beam but I have recently swapped to a full WRC style cradle.

Edited by Caddyshack on Thursday 21st April 18:54

[Caddyshack]

Most of the panels are now either Carbon Fibre or Carbon Kevlar. Only the roof and floors are metal.

Bonnet is Carbon Fibre.

Today I have started fitting the doors, these save a whopping 26 kilos over the standard pair. I had to wait for the cage upgrade before fitting these as I needed door protection. The cage is all T45 steel to keep the weight down.






I know the garage is a mess, I have too much in there so fitting the doors and boot lid etc will start to free up room to get the rest done.

I have some welding to do, I will clean up all the metal work and then epoxy it and seam seal it as I go.

Edited by Caddyshack on Thursday 21st April 18:53

[Caddyshack]

The engine was getting to the point of needing a refresh / rebuild and with a simple rebuild now £3,500+ on a Cossie without any improvements I managed to find a new home for the engine and picked up a bonkers spec fresh engine that had just been dynoed at 730hp and was built at a cost of £26,000.

I will run the smaller turbo and probably run 500 hp but with electric response as it is now a 2.2 stroker which will spin the turbo up very quickly. I can change the turbo on the same twin scroll manifold for 630hp very easily.

The car is just under 1000 kg.

[Caddyshack]

New WRC style inlet manifold.



Front WRC style hubs etc, these run the biggest discs I can fit under the 16 inch wheels. The dampers are Black Art Design all round.



You can see a bit more of the roll cage here, it ties in to the WRC style cradle that holds the diff and suspension at the rear.

[Caddyshack]

fesuvious said:

Glorius

Thank you. I know it won’t be loved by all but I had the poster of this very car on my wall as a teenager and it is very special to me.

[Scrump]

WOW!
I am a bit lost for words. Still trying to take everything in.

[take-good-care-of-the-forest-dewey]

What are the plans for the body?

GRP B + period appropriate colour scheme of something more discrete.

What a thing though. Looks great.