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Fitting a Cossy to a Scrote is similar to fitting a Pinto in as much as the basic engine block is the same, so I will only deal with the differences here to save repetition. The biggest difference from fitting a pinto, initially, is the gearbox is much bigger, so after a first trial fit you will realize that much more of the tunnel has to be removed, in fact we remove the entire tunnel and fabricate a new one which is the best way. Bought ‘large’ tunnels tend to be overly large and much fabrication is still needed to make them fit well, so scratch building is often easier in the long run.
By trial fitting from underneath the car as with the Pinto swap, you can make many small cuts to remove just enough metal to clear everything, then less metal has to be replaced when you are ready to start welding. You will have to remove the Turbo and manifold each time you fit the engine from underneath, to clear the chassis rails, but it is still easier than from above. Engine mounts may need to be fabricated which will mean removing the originals from the cross member, but make sure everything misses everything else BEFORE final welding.
Cross member to sump clearance is more of an issue as the Cossy sump is bigger than the RS 2000 sump. You must use the Cossy sump and NOT an RS 2000 one. Once the engine and gearbox are initially in place and everything clears, then you see why fabricated engine mounts are easier. Make them good and strong as you will have a powerful engine trying to break them. 4WD exhaust manifolds fit slightly better than 2WD manifolds, but with either, you must check exhaust system clearance around the steering column and it is a good idea to have a clutch cable in situ as well. The clutch cable may have to be a special made by Speedy Cables for about £45, but they will want to know EVERY dimension.
Now for the real headaches. Cossy radiators are big for a reason and if you go big power, you will need an even bigger one, AND big electric fans, AND you will need a big intercooler. Now look at the space you have to fit it all in. Most of the front panel will need to be removed and the chassis where the anti roll bar bolts on, and part of the inner wings. All of this STRUCTURAL metalwork will need replacing with an even stronger structure AROUND all the essential cooling system and intercooler.
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