Ok let up get one thing clear this car is not one for the introvert! As far as rs icons go they don’t get any bigger than this car. As a 17 year old spotty geek this was my all time favourite rs and still is today, it may be a replica … so ? this is an amazing car and an amazing build. I cannot tell the difference can you?
Michael has owned the K200 for 6 years now. The car was purchased with a a 2.5Ltr. Renault V6 engine coupled to a Renault auto box but this would only be a temporary installation as Michael intended to fit the correct Cosworth/UN1 combination at the earliest opportunity. This is how the care remained for 5 months on the original setup, not the most inspiring motoring I have experienced, but in a car that looks as if it is traveling at illegal speeds while not actually getting above 60mph, still quite enjoyable!
Michael had decided on a 16v Cosworth YB turbo engine from a 4×4 Sierra Cosworth with the power being put down via a Renault UN1 transaxle.
” It always amazes me how word gets out that you are looking for things, and after a short while, through a friend, of a friend, of a friend, I was supplied with the phone No. of a guy who had a supply of Cossie, units” A meeting was arranged, a deal struck, and Michael was the proud owner of three crates of stripped Cossie parts!
A trip to a local salvage yard and the appropriate transaxle was found, nestling in a Renault 25, £80 for the box, and £20 to cut it out and put it on the back of his truck, Bargain? we think so!
Without further ado, the car was put into the garage for the imminent transplant. The rear bodywork and chassis members where removed allowing excellent access to the engine bay, with the hoist attached, and with a sigh of relief the engine and gearbox where removed and disposed of. The whole rear end was stripped of all ancillary parts, including suspension components etc. The chassis was stripped back to bare metal and inspected. New gearbox mounting points where made and welded into place, and the chassis was then painted with Hammerite.
At the same time as this work was being done, the engine was receiving the attentions of Glen Kansley of GK Autos in Romford. He completed the full rebuild, including all balancing and lightening, and made an excellent job. Gearbox and engine where mated together with a purpose made bell housing and a hybrid clutch ( Cosworth friction material / Renault center and bearing), two Cosworth drive shafts were purchased (two long shafts from a 2wd) and fitted to the transaxle using adapter plates, the gearbox was adapted to take the new gearlever assembly.
The electrics where next for the chop, and a new Cosworth engine loom was installed along with some alterations to the original loom which at times did manage to cause us to question its parentage!
It was about this time we had a visit from a guy who was passing and had seen the car outside the garage, he turned out to be Dave Winskle, who had owned one of the first KARA 430’s some years earlier. He is a true RS200 enthusiast, and has been a great help over the past years, it is Dave who supplied the decals that are currently on the vehicle.
Also worthy of a mention is John Bass, a friend who has provided much support, technical expertise and who has an uncanny knack of locating obsolete Ford parts, i.e. original RS200 header tank (rare as hens teeth!).
With all parts back in place it was time to fire her up and go for a test drive, all was ok to our delight, the only slight problem was a lack of power under full load which was traced to a jammed fuel pressure regulator that was promptly changed, and bingo, big smiles all round.
After about a year of trouble free, very public, (What is it, How fast, How much) and fun motoring, I had managed to find an original set of 200 wheels to replace the Escort Cosworth items the car was currently wearing. A trip to Blackpool to do a deal on the wheels via specialized car covers in Bradford to be measured for a cover, made for a good day out. (Please don’t mention the trauma of being dragged onto the Big One by my wife). New longer wheel studs had to be made to allow the wheels to be fitted, after being shod with Goodyear 225/50/16 F1 rubber. This gave the car the correct period look, a vast improvement.
Another year goes by before the next stage of restoration is undertaken, this time it’s the bodywork that gets my attention.
The floor on K200 was in a poor condition, the passenger had the pleasure of being able to count the cat’s eyes through the hole!
I decided to replace the floor with 3mm aluminum sheet, to do this I first had to remove the side pods, which then revealed the reason for the rot in the floor. The side pods had been filled with expanding foam, I can only assume for sound deadening purposes, unfortunately this had blocked the drainage holes on the underside, leading to the pods filling with water whenever the car got wet, the sills and subsequently the floor then rotted. When I discovered this, I was quite worried that the chassis would be rotten, but to my relief it was ok. One of the side pods had received a shoddy repair, I presume following some accident damage, so this was repaired and at the same time the holes for the side repeaters where filled so that I could re-locate them in the bonnet as the original car. Stainless steel sills were made and the ally floor was fitted on the eve of the national kit car show 2001, nothing like leaving it to the last moment!
So far this year the car has had its oil breather system improved and a suspension overhaul by Leda in Braintree. I am currently putting together a replica rs200 dash to replace the sierra cosworth item currently installed, and fitting bigger front brakes, alloy Alcon four pots from a racing Puma, the original four pots from the front will be re-located at the rear along with the original rear calipers for the handbrake in a twin caliper arrangement as on the genuine car. The clutch will be replaced this winter after it started to slip slightly at a couple of track days.
The car is now only used during the dry summer months, and I try to attend as many shows as is possible. Next year we are planning a trip to Spa-Francorchamps and also the Nurburgring for some track action. A trip over the Alps into Italy (Italian job style) may be an option if I can talk the wife into accompanying me with the trailer (just in case!).
You can catch Michael at most of the shows so give him your appreciation tell him you saw his amazing car here!
Also Michael wants to thank his 17 year old son John who has been a great help during the rebuild and is a true rs200 fan and is off to university soon to study motorsport engineering. Good luck John … seeing the RS200 you should have no problems!
micksar@ntlworld.com
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Update – 2004
I removed the gearbox to replace the clutch which had started to slip at the end of last years show season, only to discover that it was contaminated with oil and the flywheel was quite badly burned, at first I thought the problem was a leaking rear crank seal so I removed the engine which then escalated into a full rebuild, lucky really as I discovered the head gasket was letting go, I then discovered that the oil leak was from the clutch slave cylinder! the engine has had new hydraulic tappets ( I used two sets of 8 valve golf ones which are identical to cosworth items but half the price) new bronze valve guides, total seal piston rings, oil pump upgraded (spring), GPA breather system from both sides of block, new exhaust manifold studs, new callipers front and rear, new x drilled and grooved discs front and rear, new braided brake lines all round, new wheel bearings, new clutch slave cylinder, etc. etc. etc. I also took the opportunity to make new nylatron suspension bushes for the rear, 28 in total, as the original nylon ones where shot which was causing rear steer at speed! not fun.
A friend of mine had a supply of nylatron rod which was quite simple to turn down and insert a stainless steel sleeve into. the rest of the rear suspension had a makeover with the wishbones being chrome plated and the hubs nickel plated. I have also fitted a smaller thinner radiator (from a transit) to replace the RS200 one that had sprung, this will all be controlled by an electric water pump and controller which all weighs a quarter of the original radiator.
With a new baby on the way (No6) and work commitments, progress has been quite slow so I missed all of last seasons shows. the car is almost finished now, I only have to fit the driveshafts, fill the gearbox with oil, reset the rear suspension and run her in. I was quite lucky to obtain two original unused carbon fibre RS200 seats for the princely sum of £400 !!!! these will be fitted in the new year along with the Sabelt 4 point harnesses. We have made enquiries with Conrad Wall the organiser of the Cannonball run, who is desperate for me to enter the event next year, apparently he wants something a bit different on the event, so if there are no problems after the run in I will be there, so look out for us on the box. The engine should be capable of 410bhp/400ftlb so some fun with Ferraris and Porsches should be had!
Hopefully the dashboard will be completed next year if I can locate the correct gauges, I think this will greatly improve the interior look along with the seats. I have had a great many e-mails from people throughout the world since you featured my car, it has been a pleasure replying to them as they have all been very complementary.
I have also received some photos from a guy who was on his way to an RS meet and passed us on the motorway on the way to Donnington, where he took the pics through the passenger window which my daughter found very amusing, like they say “its a small world!” I would like to thank all the people who have contacted me and look forward to many more.
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