I have to be super careful taking measurements and photos to make sure it goes back together and works. e.g. the backlash in the cam gear train is critical - you'll see why when I get the front cover off. The various magnesium covers have to be undone in a set pattern and then unstuck very carefully - you can't just pry them off. No rattle guns - the fasteners are too delicate. Once I've got this head off, I'll flip the motor over and start on getting the oil pumps off. The Cosworth manual for installing them is 4 pages long! But yes 10x times to reassemble is about right. Luckily the manual is excellent and it's a matter of taking time and thinking carefully at every step. In comparison, I pulled the vette engine down to a bare block in half a day and reassembled in 2 days!
how did I miss that??? Cosworth don't put timing marks anywhere, that degree wheel is my DIY solution
Wow, that's awesome! Looking forward to seeing more pics. And yeah, those old Holden, Ford and Chev engines are dinosaurs compared to an engine like this.
Meh, you could do it in your sleep! When I did the Lola I had NFI but it worked just fine. Local shops charge 100K for a Cosworth rebuild, I reckon 5 a year would be a nice hobby income
Might have to do the next one for you then. Yeah, that number sounds about right which is why I **** myself when you started the rebuild and asked what it would cost. We are definitely in the wrong game, that's for sure lol.
Front cover off, 3 hours of careful prising. The bearings on the centre gear clusters are a tight fit in the carriers embedded in the cover, which is magnesium and very easy to crack, plus unobtainable as a spare part. Cover off reveals the unique DFV geartrain. The big centre one at the top is the famous quill gear invented by Keith Duckworth and now widely copied. It provides just enough give to absorb high rpm harmonics, which otherwise cause gears to break. Image Unavailable, Please Login
