SHINE BRIGHT LIKE A SAPPHIRE
The Ford Sapphire is often considered a forgotten classic, but lumbered with Cosworth mechanicals it’s simply unforgettable, and Leigh Edwards knows that more than most
Upon hearing the word ‘Cosworth’, palms tend to moisten and mouths often salivate, and it’s no different for Leigh Edwards; the owner of this 1989 Ford Sapphire Cosworth you see sprawled across these pages. Cosworth-powered Fords have always been a popular breed, and that’s prominent now more than ever, with prices at the highest they’ve ever been, but, if like Leigh, you’ve been lucky enough to acquire one yourself, then it’s probably a good bet to hang on to it. “The Sapphire is a car I’ve wanted to own since I was a teenager – I still can’t believe she’s mine, to be honest.
“I purchased the car around ten years ago, and to say it was a bit rough around the edges is an understatement. That didn’t put me off, though – I fell completely in love with her. In the beginning, I used it
as a daily – just for a few years while I collected the parts I needed to bring it up to scratch and make it mine,” says the 35-year- old process technician.
“I can honestly say that I’m a Ford man through and through. I was bought up around Capris, as that was the only car my parents ever owned. My first car, and of course first Ford, was a Ford Capri 1.6 Laser, and would you believe that I still have it?! She’s currently being restored – granted, pretty slowly, but restored nonetheless,” Leigh told us.
It’s no surprise to learn that Leigh took no prisoners with the Sapphire build, nor should he – he was determined to make it perfect.
A car is often our pride and joy and to do a half-hearted job is a no-go to a true enthusiast. But, this restoration, like many, got out of hand. Leigh started out with a ‘standard’ restoration in mind – back to stock, clean and unmolested, if you will – but it rarely ever pans out that way, and the Sapphire was no different. The first job on the restoration to- do list was restore the underside, not that it was particularly rotten or spoiled, it just needed a freshen up. “If you’re going to restore a car, you do it properly. It’d make no sense to get carried away with all my other ideas, without each aspect being right. But, it’s probably safe to say that I got carried away when restoring the Sapphire… for reasons I still deem understandable ( some wouldn’t).” While Leigh tackled the underside, he went and fitted a Toyota Supra differential – no mean feat, then. “Even though I hadn’t decided exactly what route I was going to go with the engine and output, I figured it was going to need decent handling, especially with all the bhp figures flying around my head,” Leigh said.
“The Sapphire is a car I’ve wanted to own since I was a teenager – I still can’t believe she’s mine”
Suspension was next – naturally. Leigh went on to powdercoat the suspension and fit Bilstein 909 Tarmac coilovers to the front, and Avo coilovers to the rear. Polybushes were also fitted all round. To further improve on the handling of a car whose bhp, at this point, was unknown, front and rear strut braces were fitted, alongside an Escort Cosworth rear anti-roll bar. New brake lines were added, together with some not-so-shy 330mm front Brembo brake discs and pads, with 300mm Brembo discs at the rear.
Tidy breaks should be housed by tidy wheels, right?! Well, Leigh plumped for some pretty plush 18in WRC Compomotive Cromodora-style FMV1880 wheels! Leigh built the car by himself, with the exception of the paintwork, which was left to the ‘professionals’. Speaking of paint… “Keeping it as aesthetically original as possible was the only way to go, really. Flint Grey was the colour and Amo Autos did an incredible job of respraying it for me. She looked just like new, with the entire car getting a full coat, machine and polish, as well as door shuts, oh and the engine bay”. An RS500 front splitter, as well as RS500 fog lamp grills, and not to mention a Rouse rear spoiler and Aerocatch bonnet catches, completed the ‘racekor’ exterior.
While Amo Autos in Blackwood, South Wales, tackled the paintwork, Leigh decided it was time to sort the heart. During his ownership, he’d gathered together all the bits needed for a new lump up front. He sourced a new 200 block (98 cast), a Cosworth racing oil pump, pocketed 7.6:1 Cosworth racing pistons, a WRC four-layer head gasket, Nick Waples touring carspecification head, a BD16+ inlet camshaft, and Quaife vernier pulleys, as well a number of other mental additions to make this thing shift.
Leigh built and assembled the engine himself and fitted it to the car as soon as it was back home from the body shop. So, what’s the power
output we hear you ask?! Leigh managed to get a whopping 550bhp out of it, along with the help of an ECU map from SCS’s Harvey Gibbs. “I know 550bhp isn’t exactly standard, but at least I kept it original-ish with the paint…” Leigh said, chuckling to himself. Not to mention the additional 100bhp from the NOS he also has stashed in it! A Bosch WRC fuel pressure regulator, a TiAL 44mm external wastegate and an Airtec ‘Gobstopper’ topfeed intercooler, all help to keep that power in check. The power is then delivered through a rebuilt T5 gearbox with AP Racing six-paddle clutch system, and Toyota Supra rear diff.
Engine in and running, Leigh stumbled upon an original interior in mint condition. “I somehow managed to source an original interior for the Sapphire that was like new. I fitted the front seats, then the rear bench and a six-point roll cage, which was essential for the odd track day – a guilty pleasure of mine”.
The Sapphire is ‘technically’ a complete car, but it’ll come as no surprise that there’s still a few things left that Leigh wants to do. He told us that next on the list is a Tremec gearbox, complete with aftermarket management system, anti-lag, and a target power output of 700bhp! “I just love building cars, especially ones I’ve dreamed of owning. It’s not like building the Sapphire has been all plain sailing, there was even a pretty serious fire along the way, oh and a failed oil pump also held things up, but you keep at it. I’ll let you know how I get on with the new changes!”, he said. We look forward to seeing what you do next, Leigh. Watch this space!