Erika the 1.8GL Sapph

[TwinTurbo]

Ok...

Some of you have known me for quite some years now, and throughout that time I have been very slowly welding back together my 1.8GL Sapphy, collecting parts, engines, planning, changing plans and claiming it will be ready "Next summer"

Initialy. WAY back the intention was for the looks to be straight Cossy 4x4. That has never change and everything is in place to do that. ( bar the set of 17" Polaris wheels that have replaced about 6 other sets in the time off the road! )

Engine's plans have evloved..

Inital plan was a Pinto turbo.
Then I got a stock 12V,
Then I got a 225 TwinTurbo 12V
Then a 225 TT running 253BHP
Sold both them,
Put the Stock 4i In a DOHC
Bought another 12V put that in TAPS's Thundersaloon.. ( Ran out of time on that car.. )
Bought 2 24v's, sold 2 24v's
Bought 2 24v's....

And it's with the 24V we stay... YAY.. the current engine is in the process of conversion to 4x4...

The car was always going to be 4x4, which has been the big hold up. My car was an 87 Year, and has neither the mounts for an MT75 or the tunnel for the Prop. The work to convert the shell has een in progress for the last year or so.. But in the last 2 weeks much work has taken place to get this sorted.



Ok, here's the pictures of the progress on the tunnel ( well I have progressed a little further but they will come later )

It's not pretty, and at some point in the future will be fully reworked..

the drivers side is more difficult due to the need for the clearance on the front prop.

Note that all welds are being linished regardless of whether they will be under carpet or not. And also that all seams are wellded top and bottom where possible.

My welder is a bit pants, but I can't just blame that for some of the poor welds..

I decided to use the sierra inner pannel on the drivers side, but on the passenger I have decided to fabricate from scratch...  The passenger side was previously nearly complete but turned out to be out of line

Anyway..

Drivers side..





TT

[Taps]

Bout time ya done a post on that TT, Looks like ya went a bit OTT with how much you cut out of that tunnel m8.

You had a lot of rain up there ya house has shrunk  

[TwinTurbo]

Yeah, need to start digging for old photos..

It's difficult working in a small single garage, everything has to be done primarily from the top.. So I ended up cutting back a fair bit.. It will do the job for a couple of years...

Not stopped raining in months....  

And just noticed the black soot on the garage door, that was caused by Erika and a dodgy Pierburg 2e3... Not that the soot is there any more, and the door is blue...

TT

If I was to do it again from the start, I would just cut into the tunnel where the crossmemebr goes and fully fabricate the mounts.. But I thought using the 4x4 tunnel would be a good idea!!!

TT

[TwinTurbo]

Moving day part 1....

In order to move house the Sapph had to be take to a m8's house whilst we move. So yesterday she was transported to a temporary home. 1st time she has been off site in 7 years!!!! 1st time out uncovered overnight in 6 years!

She did not want to go, the fule pump feed packed up as we aproached the trailer!! winched her onand used a booster pack on the pump wires to get her parked up...














Thanks to richard at cartrans http://www.cartrans.co.uk]http://www.cartrans.co.uk for swift, freindly and efficient service.

Next stage in a couple of weeks...

TT

[TwinTurbo]

She's now been back at the new house for a few weeks

Finaly I now have a downpipe that fits properly, and an exhaust that fits to that!!! Ok the backbox is a little bit cosy with the bumper.. But that can be fix..

One less thing to sort out,

Oh and Lambdas should be sorted during the week...

TT

[TwinTurbo]

Erika in her glory days.



TT

Hatchback boot latch converted to sapph boot latch and fitted. It made a huge difference to me!!!

The fuel pump loom in boot has finaly been soldered up ( I needed a lead to convert from 88 to 92 spec. )

And I plonked the cossi gril in place ( I got this one almost free in the scrappy with a pair of hrdlamp protectors )





TT

After issues with getting her started, I managed today and moved Her a few feet ( I need to demolish the garage )

TT

[TwinTurbo]

Right...

Few little steps...

Have tried cleaning the ISCV to sort out a hanging throttle but eventualy sufficed with leaving the ISCV off..

I have also connected up the four ABS sensors ( dangeling not in situ ) and the warning light goes out. So at the very least it passes the static test  

I have managed to squeeze the instument cluster past the non adjustable colum and got that in situ, along with 3 of the dash switches.  And also fitted the AWS display, which seems to sugest every door is fault or open!!! probably true..

I have taken all the crap out of the inside.... Not sure what to do next as it needs partly stripping down again and painting.. And I can't do that till the scorpio is fixed and on the road..

TT

[TwinTurbo]

Few minor things attended to...

Found the wiring to the horn.
Found the gearbox wiring.
Fitted front door cards
Found the ECU bracket and it's ready to fit ( need to weld in mountings for it )
Fitted the Cooling fan switch and boss as per marty's picture a few pages earlier.
Cleaned up the plugs.
Found the new drivers side rear caliper

May not sound much but it's an achivement the way things are going!!

TT

[TwinTurbo]

I am now scorpio less, the old GT has gone and the donor Granada has gone...

So, that leave the daily Galaxy 2.3 Ghia and Mondeo 24V Si  ..... And then the MK1 golf resto and the Erika...

That means that there is no scheduled works for desposing of cars  

That means that I have time to look at the Sapph and Golf    

Today, I fitted the airbox
Today, I fitted the monjeifed granada power roof ( I may have to revisit this as It's not gr8. )
I cleared out the crap from the boot, fitted a replacement water sensor..

Not a lot but now I am in the position to tackle it as and when time is free.

And with lighter warmer nights on the way I will be more inclined to do stuff.   I need to get a recon caliper for the passenger rear.

I will try and take some pics tomorrow if I get a free moment from the kids.

TT

[TwinTurbo]

Just a few random shots and shots of the sunroof... Still need to screw the fram down fully.

Whole dash has to come back out so I can take the door of to make the gromet hole bigger for the 92 spec wiring. And weldd in an ECU bracket.
been with me for 15 years that number plate...


As you can see the frame had to be trimmed as it lips down and fould the hump in the roof.  The motor bracket sits miles from the lower mounts???





Wifes Mono 24V Si




I fitted up the 6Pot rev counter today and connected the feed under the bonnet ( this should have been done last year but the +12V ign feed on the connector from the car seemed to be dead. I need to investiagate this further.

The counter seems a little erratic, but it's reading about the right level.

TT

[TwinTurbo]

FANTASTIC 20 Minuets.......

Yes, Earlier today I found the engine bay loom from my old 24V Frogeye.. And on it were the two two pin plugs that would mate up to the fans....

And a relay... I studied the Scorpio wiring bible and worked out what this relay does. It runs the fans in serial ( so 2 at half speed ) or in paralel ( 2 at full speed. )

So before tea, I stripped this bit of the loom out and hooked it up temporariliy in place... And WOOOHOOO...

2 speed fans. Now I just have to work out their control from the dohc fan swithch



TT

[TwinTurbo]

Right... A bit of an update, I have more or less two months to get Erika roadworthy for ford fair.

The must do list.

Fit ABS Sensors
Tweak Brake Line near manifold
Fit Heat Shields
Fit Proper starter cable
Fit Speedo Cable
Fit Reverse Light Loom
Fill With Coolant
Swap Rear Calipers
Swap Wheels
Fit Alarm
Fit Rear Door Electrics
Fit Front Door Electrics - Need to Mod a pillar for 90 spec looms
Fit ECU mounting Bracket
Tidy Under Dash Wiring
Torque Up Rear Suspension
Fit rear Light Boards
refit Dashboard
Refit Seatbelts
Refit Interior Plastics


That's about all I can remember.

So yesterday,

I fitted the rear spoiler ( hmmm not on the list ). Also fitted the headlamp protectors.

Today, I took off both front doors, modded the A-Pillar, swapped the door looms for the ones with full electrics.
Made an ECU mounting braket, tidied up the wiring, all in place... Front kick pannels..

Then found the ABS light now will not go out ( BALLS.. )








So a coule off the list and one on...


Fit ABS Sensors
Tweak Brake Line near manifold
Fit Heat Shields
Fit Proper starter cable
Fit Speedo Cable
Fit Reverse Light Loom
Fill With Coolant
Swap Rear Calipers
Swap Wheels
Fit Alarm
Fit Rear Door Electrics
Fit Front Door Electrics - Need to Mod a pillar for 90 spec looms
Fit ECU mounting Bracket
Tidy Under Dash Wiring
Torque Up Rear Suspension
Fit rear Light Boards
refit Dashboard
Refit Seatbelts
Refit Interior Plastics
Fix ABS

[TwinTurbo]

Ment to be out helping a Freind with his company, but he's stuck on another job...

So I went out to try and track down this ABS fault... All Sensros reading ~1050 at the ECU Plug, Checked for loose earth, Checked the fluid level which is WAY HIGH! need to lowe that. Started checking relays and their feeds and came across some white oxide on one of the relay fuses, I pulled this and swaped it for the other pump relay fuse. Light's out..

BRILL...

Put it all back into the new braket. Still works ... SUPA!

GET ME TO THE ROAD LIST
Normal - To Do
Bold - Done
Italics - Woops forgot this added to list

Fit ABS Sensors 1 rear done, 3 left
Tweak Brake Line near manifold
Fit Heat Shields
Fit Proper starter cable
Fit Speedo Cable
Fit Reverse Light Loom
Fill With Coolant
Swap Rear Calipers 1 done, 1 to do
Swap Wheels
Fit Alarm
Fit Rear Door Electrics
Fit Front Door Electrics - Need to Mod a pillar for 90 spec looms
Fit ECU mounting Bracket
Tidy Under Dash Wiring
Torque Up Rear Suspension
Fit rear Light Boards
refit Dashboard
Refit Seatbelts
Refit Interior Plastics
Fix ABS
Fit Boot/Fuel Release
Sort Rear Courtesy Lamp
Have Windscreen Replaced

[TwinTurbo]

I have not updated this thread in a long time, partly because not a large amount has hapend. the details of what has gone on can be found on the sierra club thread

http://forum.fordsierraclub.co.uk/viewtopic.php?f=64&t=21185&start=225


I recenly invesitgated the state of a rust hole in the boot floor, it turned into a big hole and a scrap chassis rail. More welding to do  


But I have been moving on, sorted out the speedo cable and reverse/vss loom today after a long day out at Kielder. It's also up on 4 stands so getting run in gear a few times to free it up a bit.

TT