Author Topic: Cosworth Engine Ready for Installation (Read 38407 times)

82expghost · « **Reply #60 on:** April 09, 2012, 10:24:10 PM »

at first glance, it looked like the 4x4 trans out of the euro escort

cossiepinto · « **Reply #61 on:** April 14, 2012, 09:34:41 PM »

OK, the headers fit now, with the slight mod to the frame.

I cut out a small notch in the frame for insurance after I removed all of the porch the battery tray used to sit on.

That inner fender removal gives me all the room I need to work the headers into place. Now I'll make a panel to re-close the area, but it will still be removable when I need to remove the headers for any reason.

I had to modify the passenger side motor mount slightly also, but that wasn't a big deal.

I did discover why I'd had so much trouble putting the transmission cross member back in place, though. The extra thick aluminum cover on the Quaife transmission just barely touches the tunnel at the right rear corner. Also, the little breather fitting sits up against the tunnel solidly, which was making it hard to get the cross member to bolt up. I'll trim a spot out for those in the coming days. It won't require removing the engine. I'll just remove the cross member and let the engine tilt back and the transmission to drop a little.

Here are a couple of closeup pics of the pipes and the mod.

Paul

Pintosopher · « **Reply #62 on:** April 15, 2012, 01:45:49 PM »

Ahh..... I just get aroused looking at this thread! Rock On Paul!

Starliner · « **Reply #63 on:** April 15, 2012, 06:21:10 PM »

Awesome project and I admire the workmanship.
That engine is going to sing a glorious sound at full song!

When I am in Hong Kong I always pick-up British car magazines.
I love the magazine "Fast Fords". Every issue is full of Cossie goodness. I think you can subscribe here in the states.
I love the British Escort Mexico's and Cortina's fitted with the Cosworth YB'T' engine.
I am curious why you did not go the YBT turbo route?

I will continue to check in and watch your progress. Keep us updated, the pictures are great!

cossiepinto · « **Reply #64 on:** April 15, 2012, 09:02:07 PM »

Thanks for the good words, Starliner.

Cosworth offered this engine in kit form. They also offered a mechanical valve train engine (YBG), but I wanted a lower-maintenance, more streetable engine, so I bought the YBB.

I like the sound of a naturally aspirated engine sucking air through Weber air horns.

I admit, however, that I didn't have the turbocharger mounting brackets machined off the head!

Paul

cossiepinto · « **Reply #65 on:** April 28, 2012, 08:53:13 PM »

Here are some photos of the final fit for the headers. They fit with about an inch of clearance at all critical points. The pipe sent with them will fit also, but it'll need to be indexed just right to clear the bell housing.

I'm now working on placing an inspection plate on the transmission tunnel, so the breather/fill plug won't hit the underside of the tunnel. I found out the hard way (almost impossible to bolt up AND then the plug isn't removable with the transmission in place) that I needed some more room. I'll send out some pics of that, too, when I get it all done.

It's been a little slow going this past couple of weeks: out of town last weekend and this weekend is my bride's birthday, so no Pinto work then!

Paul

cossiepinto · « **Reply #66 on:** April 28, 2012, 09:11:56 PM »

Ok, here's what's up with the transmission tunnel modification so far.

The Quaife dogbox has an extra-thick top cover (about a half-inch) and the filler/breather stands up about another inch (not including the threads to screw it into the cover).

My first clue that I was out of room was when it was very difficult to bolt the transmission cross member in.

Of course, I ignored that clue. Luckily, I had to remove the engine again to fit the headers. This time, remembering how difficult the bolt-up was, I decided to remove the filler plug/breather and put in a temporary plug 'til I got the engine/transmission in. That worked great!

When I crawled underneath to replace the temporary plug with the filler plug/breather, only then did I realize that I had no room! I couldn't even get my fingers in there....

Hence the hole in the tunnel, etc, etc.

It's going to work out fine, though. The plate on top can be removed by drilling out rivets, if necessary, and there will be a cap that I can open to fill the transmission, if need be.

Paul

Reeves1 · « **Reply #67 on:** April 28, 2012, 09:41:03 PM »

Cool project ! Been watching all along as you go.

The crank/trans/diff is in line well ?

cossiepinto · « **Reply #68 on:** April 28, 2012, 10:22:55 PM »

So far as I can tell, all is aligned well. The only iffy part might be the pinion angle, as I'm not using a standard rear end. When I talked to the guys at Speedway Engineering, we settled on a standard pinion angle for the mini-quick change I bought from them. I can adjust it as necessary.

The Quaife is based on the Pinto German Hummer gearbox, so the standard Pinto bell housing (2 liter) bolts up nicely. When I decided to use an internal slave cylinder clutch bearing, I sent the measurements to Taylor Race Engineering in Plano, TX, to get the proper input bearing collar length.

If the Quaife had the standard sheet metal trans cover and no breather stack on top of it, the transmission would have slipped in with no worry.

You can see the mini-quick change in this pic with the fuel cell not yet installed.

Paul

johnbigman2011 · « **Reply #69 on:** April 29, 2012, 01:01:47 AM »

Paul, what could anyone say. The car is one High tech piece of work for sure.

cossiepinto · « **Reply #70 on:** April 29, 2012, 10:15:04 AM »

BigMan,

I don't know how high-tech the Pinto is; it has some goodies on it, but they're all pretty old-school. I do have electronic ignition, though...MSD. Old school high-tech!

Paul

Pintosopher · « **Reply #71 on:** April 29, 2012, 04:51:12 PM »

Paul ,
This is pure Pinto fabrication Porn.. I'm addicted and I don't care who knows it! PM me if you ever want to do this again. Make sure this car is in every Ford mag .. I salute you sir..

Pintosopher, Student of the Wizards, Apprentice to the Fab Gods!

cossiepinto · « **Reply #72 on:** May 06, 2012, 03:39:14 PM »

Thanks, Joe, but I don't want you to go blind viewing this project too often!

I'm wrapping up the transmission tunnel mod this weekend. I had to fabricate a cover and a short stack to clear the oil breather/filler on the top of the gearbox. I made a lid for it, but am not satisfied, so I'm going to try again.

I need to scare up a 3 3/4 inch diameter aluminum disc to make the lid. I'll look for something this week.

Right now, the plate is clecoed in place while I wait for my powder coat friend to do a batch of textured black...should be late this next week.

Paul

johnbigman2011 · « **Reply #73 on:** May 06, 2012, 04:25:06 PM »

You could probably use a fuel bung cap like they sale at So Cal. I purchased one for my t-bucket . I think it would fit nice and look custom like the rest of your car.

Just my thoughts.

I do enjoy turning on the forum and seeing new post about your car!!

Keep it up there Mr. Cossie

West Texas has a pin in it for my power tour that the wife and me will be doing, either this Fall or next Spring

cossiepinto · « **Reply #74 on:** May 06, 2012, 04:37:39 PM »

Bigman,

That might have worked if I'd have thought about it in time. I did need a little extra room to get my fingers in, so I could unscrew the thing, though. A fuel bung might have been a little too small.

Make sure you take a detour and come by San Angelo when you go on your tour!

Paul

Srt · « **Reply #75 on:** May 07, 2012, 03:34:07 AM »

Quote from: cossiepinto on April 29, 2012, 10:15:04 AM

BigMan,
I don't know how high-tech the Pinto is; it has some goodies on it, but they're all pretty old-school. I do have electronic ignition, though...MSD. Old school high-tech!
Paul

imho, hi tech means attention to detail, flawless (as much as it can be done) workmanship and the willingness to experiment. i suppose you could throw in some modern technology but 'old skool' is really just a way of saying that you can use your imagination and the technologies at hand to perfect your dream

cossiepinto · « **Reply #76 on:** May 07, 2012, 07:05:10 PM »

Thanks for the feedback, SRT.

My problem has been that as my capabilities/pocketbook have become more "capable", I keep doing do-overs. My wife wonders if I'll ever finish. It seems every milestone uncovers a new challenge. Right now, making everything fit has been slow, especially with only weekends to make things happen.

johnbigman2011 · « **Reply #77 on:** May 07, 2012, 07:12:28 PM »

Paul, how long have you been working on the Cossie Pinto.

cossiepinto · « **Reply #78 on:** May 07, 2012, 10:05:46 PM »

BigMan,

I bought this car in 1988. It had a hole in the side of the 2 liter engine and the back floorboard and spare tire well were full of rainwater. After getting a clear title, the roll cage went in, and I did a few things like putting an 8" rear end in and designing a big brake system for it. My first plan was to build another 2 liter or possibly buy a BDA (actually a 1700cc BDR) engine, but this plan evolved over time to the YB Cosworth engine.

There were times when the car sat for years (once for 3 years in a row) untouched, especially when we were raising our kids and getting them settled in life, etc. The Pinto always was last in line when it came to the budget.

Now, we're empty nesters, and time and money are a little more plentiful, hence the upswing in activity and spending. My wife now wants me to "finish the darned thing", and I'm happy to oblige. It's the Pinto's turn.

Funny thing is, over the years, with the Pinto front end becoming a popular piece for hot rodders who want to put independent front suspensions in, things I never dreamed of are now available: tubular a-arms and brake/hub packages, and nice shocks (although I scored a set of Konis from Racer Walsh years ago), etc. And, with Pintos becoming popular in mini-stock circle track racing, other suspension bits became available.

So, the short answer is the Pinto's been in the family for 24 years but it's resided in a nice dry garage, untouched for many of those years, waiting its turn.

Paul

cossiepinto · « **Reply #79 on:** June 02, 2012, 11:15:43 AM »

Ok, here are a few pics of what's going on lately with the Cosworth Pinto.

I'm still waiting on the transmission tunnel cover to get back from the powder coater, so I made the engine/oil tank vent hoses up, permanently installed the carbs, headers, radiator, oil cooler, and oil tank.

I also timed the distributor. There's only one way it can go, since the right angle cap can only point one way. It's easy to monkey around with it, since you don't have to worry about the oil pump drive falling off the bottom into the pan when you yank the distributor up. I guess the added expense of the dry sump was worth it! Haha.

Once the transmission cover is in place, then will come the tedious wiring exercise. Hours I want to work on the thing are limited now that it's 100 degrees almost every day here by afternoon, sometimes earlier.

Enjoy.

Srt · « **Reply #80 on:** June 03, 2012, 03:30:45 AM »

Quote from: cossiepinto on May 07, 2012, 07:05:10 PM

Thanks for the feedback, SRT.

My problem has been that as my capabilities/pocketbook have become more "capable", I keep doing do-overs. My wife wonders if I'll ever finish. It seems every milestone uncovers a new challenge. Right now, making everything fit has been slow, especially with only weekends to make things happen.

methinks your loving wife might be a bit bit more miserable if you weren't able to 'do it right'

cossiepinto · « **Reply #81 on:** June 03, 2012, 09:37:12 PM »

I try my best not to make her miserable....b een married too long not to have learned that lesson!

ponyrancher · « **Reply #82 on:** June 04, 2012, 04:00:36 PM »

Just setteled a fight between my grand kids and found your thread. I had always dreamed of putting a cossi head on my pinto (1973 mini mark IV) after I saw the advert for 400 horses @ 8000rpm. Of course I am incapable of doing the work you have done let alone the quality you have done also. So thanks for letting me live my dream in an alternet universe.

cossiepinto · « **Reply #83 on:** June 04, 2012, 04:20:12 PM »

You're welcome ponyrancher.

I've become more "capable" as time goes on, making mistakes and do-overs.

Four hundred horsepower from a naturally aspirated 2 liter YB Cossie is possible, but it'd be awfully rude and waspy in normal street use. Turbocharging would make that horsepower more easily, but it's still costly. I've seen claims of 700+ for race-tuned turboed YBs.

This little engine is tuned to about 200 horsepower, should idle normally, and will rev to about 7800 if it has to. I have set the rev limiter at 7200 rpm to start with.

Paul

cossiepinto · « **Reply #84 on:** June 05, 2012, 08:44:18 PM »

New Weber condoms came in today. I hope I don't have to keep covers on much longer, but these fit nicely and should seal out dust better. Can't wait to put the filters on and light it up.

1oldtimer · « **Reply #85 on:** February 18, 2013, 11:47:23 PM »

I know this is an old post but any more news.......I'm hooked. Now I want to find a Cosworth head for my 2.0.

johnbigman2011 · « **Reply #86 on:** February 19, 2013, 12:17:18 AM »

1oldtimer I spoke with Mr Cossie just the other day, and he stated that he is down to running wiring and such.

I'm going to make a point to go by his place on my way back from Idaho in May.

It is an awesome build for sure.

cossiepinto · « **Reply #87 on:** June 09, 2013, 11:06:52 AM »

Well, I'm still working on this thing, and judging from the hits I'm still getting, not everyone has lost hope that it'll ever get finished.

Here are a few pics of recent activity:

1- I had to redo the breather/filler tank for the mini quick change rear end, because the under-the-floor tank was so low it wouldn't refill the rear end quickly enough. I mounted a different one (mini-sprint type) on a vertical plate in the trunk, next to the fuel filter. You can see some plumbing there as well. The fuel pump is inside the cell, so that makes for a much less crowded area.

2- Yesterday I attached the calipers to both the front and rear. I only had to machine a tiny amount off the RR caliper to get it centered on the rotor. Everything's a tight fit with new pads, but that fit was just too tight, so I spot faced the caliper ears a smidge and all's well now. Funny, none of the other calipers required machining or spacers.

3- Just a look-see at the front caliper. Note how the hubs match front and rear. Speedway Engineering had matching stuff that I really liked.

4- HELP! Check out the red arrow in the last pic. What's missing? The brake hose tab, that's what. It's also missing on the other side. I spent a couple of hours fingering through all my stuff and they are either playing a masterful hide-and-seek, or just plain gone.

If anyone has a couple (I'm pretty sure right and left are the same), I'd gladly buy them from you. Please let me know.

Pintosopher · « **Reply #88 on:** June 11, 2013, 11:23:47 AM »

WARNING : Prolonged viewing of this Thread can lead to Mental instability, and even a possible PDE-5 inhibition effect that may lead you to a therapist for extreme Pinto Lust. Prolonged exposure in excess of 4 years can cause serious financial and perceptual damage to your Psyche. You'll know it's too late when you begin imagining your household Plumbing with AN fittings and Earls hoses..
See your Life for what it can be , and build your horse to suit!

74 PintoWagon · « **Reply #89 on:** June 11, 2013, 11:51:11 AM »

Very nice setup..

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Author Topic: Cosworth Engine Ready for Installation (Read 38407 times)