SAPPHIRE COSWORTH
ENGINE 2.0 litre Ford Sierra RS Cosworth YB turbocharged inline four with honed bores, knife edged crankshaft, ported head, BD14 intake and BD10 exhaust camshafts, Mahle bearings, shells and piston rings, K&N Group A air filter, Siemens 55lb fuel injectors, Bosch Motorsport 044 fuel pump, T34.48 turbocharger with -34 actuator, Pro Alloy RS500 style intercooler and alloy radiator, replacement valve guides, engine wiring loom and fan wiring loom, Sierra RS Cosworth L8 ECU with Motorsport Developments chip TRANSMISSION Rebuilt Ford Sierra RS Cosworth T5 five-speed manual transmission with Ford Sierra RS Cosworth 7.5in rear limitedslip differential and AP Racing organic clutch kit SUSPENSION Koni adjustable dampers with SPAX fast road springs all-round, Powerflex bushes throughout BRAKES 283mm Tarox grooved discs with OEM Ford Sierra Sapphire RS Cosworth 2wd brake calipers front, Tarox 273mm grooved discs with OEM Ford Sierra Sapphire RS Cosworth 4x4 brake calipers rear, Ferodo DS2500 pads all round WHEELS & TYRES 18x8in Compomotive TH1882 alloys with ET35 offset all-round, 215/35R18 Toyo Proxes T1-R tyres all-round EXTERIOR Original Sierra Sapphire RS Cosworth bodyshell in Diamond White, OEM Sierra Sapphire RS Cosworth 4x4 vented bonnet INTERIOR OEM Sierra Sapphire RS Cosworth 2wd interior with cloth Recaro seats, genuine Ford RS floormats, centre vent blanking plate with auxiliary Stacks exhaust gas temperature, voltmeter and boost gauge, Kenwood KDC W311 head unit. been built up by a previous owner – back when it lived under the bonnet of a different Sapphire – and featured some serious spec. Highlights include a ported head, a knife-edged crank, and BD14 inlet and BD10 exhaust cams. The Saph had just found a new heart.
“I thought it just as well to fit the 200 block in the Sapphire and sell its original engine,” says Gordon. “It was cost effective.” The enhanced engine received a quick refresh, gaining Mahle bearings, shells and piston rings and a new head gasket. With the fourbanger in bits, Gordon couldn’t resist the chance to tune and added a wasted spark setup, a Motorsport Developments ECU chip and a Garrett T34.48 turbocharger. The enhancements are joined by a K&N Group A air filter, a custom exhaust, a Bosch 044 fuel pump, a pair of new wiring looms and a Pro Alloy intercooler and radiator. The result is an estimated 350bhp and 320lb.ft of torque.
Before the 200 block was dropped under the vented 4x4 bonnet of its new Sapphire host, Gordon took the chance to add a showroom shine to the lesser seen parts of his four door Cossie. “It was quite messy underneath and covered in a Waxoyl-style coating that I don’t like at all,” he explains, “I prefer a fresh coat of paint underneath. I cleaned the engine bay down too; I removed all the grubby, oily marks but didn’t add any new paint.” A fully rebuilt T5 transmission – “easily the best changing T5 I’ve ever used,” smiles Gordon – and an AP organic clutch also complement the new engine.
The Saph was straining for a chance to slay but there were some details to sort out first. Three Stack auxiliary gauges were fitted to the centre vent of the dash and Gordon went looking for some new alloys. He settled on a set of Compomotive TH1882s. “I’d bought them for my three door Sierra originally but I decided to be a bit different and drop them on the Saph instead,” he smiles. “In my opinion,
they’re the choice for any Cossie!” The suspension had also been due some attention – Gordon feeling that the Koni adjustable dampers and SPAX fast road springs already fitted to the car slung the chassis that little bit too low – but the sheer stance imbued by the rally-inspired rims spoke for itself and the suspension stayed. With that, the Cossie was complete.
There’ll be no build bloat here either: given the hardcore headbangers already in his possession, Gordon has no urge to add any more power to his semi-subtle Saph. Other changes might come in time, with a Gripper rear differential, stronger stoppers and a refreshed rear beam all floated as possibilities, but it’s a case of if not when.
The four-door can’t claim to be the fieriest Ford ever but it counters with something far more useful: real-world usability. “It’s just a road car,” Gordon explains. “It gets used exclusively on the road.” Though the Saph spent much of 2016 and 2017 off the road whilst various track rats received attention, it’s been laying roots and rubber on the Scottish pavement ever since our photoshoot. “It’s as much fun as some of my other Cossies – if not more fun – because it’s rear-wheel drive,” Gordon smiles.
Don’t just take his word for it. The 350bhp sports saloon has been shouting its playful personality far and wide. “A friend of mine owns a 526bhp Sapphire, and I took him out in it for a run one day and he was shocked by how lively it is for a Stage 3 car. He hasn’t been in a rear-wheel drive one recently, you see!” Even Gordon’s pregnant wife has enjoyed a turn behind the wheel, while the Saph has also featured in two couples’ big days. Show appearances are stencilled in for later this year but, above all, Gordon is using the two-wheel drive Sapphire to drive, drive, and drive some more. “It’ll be nice to see how things go through the rest of this year,” he smiles. “I’m really hoping to use it as much as I can.”
With a mandate like that, you might imagine the mighty fine four-door will be guarding a corner of Gordon’s garage from here to the horizon. Woah there! The future isn’t quite that clear. “Whenever it appears online, I get offers from people trying to buy it,” he admits, “and that leaves me undecided about whether to keep it. That said, I’ve owned so many over the years that I’m reluctant to sell this time… with prices going the way they are, I’m not confident I’d ever be able to buy another as good as the one I’ve got! It doesn’t miss a beat and it’s great to have one that’s usable.” There’s merit in the middle way.