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The Tuning Team Behind Cosworth's Success

The tuning team behind Cosworth's most successful F1 engine is known for their expertise in rally racing, wacky wings, and creating the sickest Escort ever made. But few people know about their humble beginnings as engineers at Lotus.

In the 1950s, Mike Costin and Keith Duckworth were two of the talented engineers at Lotus. However, they felt a little limited in what they could do. They had ideas for innovative racing engines, but their creativity was restricted by their main employer's restrictions.

To pursue their passion for building race engines to their own specifications, Mike and Keith came up with a plan to start a company on the side. Little did they know that this decision would lead them to one of the most successful F1 engine manufacturers in history.

As luck would have it, their bosses at Lotus, big dog Colin Chapman, were receptive to their proposal. Mike and Keith presented their plans to Chapman, and the rest, as they say, is history.

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WEBVTTKind: captionsLanguage: en(car engine revving)(car backfires)- It's the tuning team knownfor rally racing, wacky wings,and the sickest Escort ever made.But did you know they also madethe most successful F1 engine ever?(car engine roaring)This is the episode of Up toSpeed where I want more carsin it than any otherepisode of Up to Speed.(car engine roaring)This is everything you need to knowto get up to speed on Cosworth.(upbeat music)It all started in the 1950'swith a couple of blokesfrom Northampton, England.Mike Costin and Keith Duckworthwere engineers at Lotus,but they felt a littlelimited in what they couldand could not do.So they came up with aplan to start a companyon the side building raceengines to their own specs.But like any small startupthey ran into a problem.That's when they went to their boss overat Lotus, big dog Colin Chapman.And they were like, "Mr.Chapman, we would like"to start designing raceengines for race cars."But laddies, that'swhat you're doing here."Don't you like my engines?"Quack, quack, quack, quack."Yeah, like Duckworth said, we love Lotus."We just want to do our own thing."But gentlemen, why do you need me?"Quack, quack."Oh, it's money you're after."I love you boys."Here's all the pounds you need."But I have a few conditions."So Costin and Duckworth started Cosworth,a portmanteau of their last nameswhich makes you think would we be talkingabout them now if they namedtheir business "Tinduck."In 1958, Cosworth EngineeringLimited set up shopin a rat infested oldgarage in Northampton.Colin Chapman agreed tobankroll the new companybut with a few conditions.Duckworth was free to leave Lotus,but Mike Costin, who had justsigned a new contract, hadto stay on as an engineer.And Lotus had first dibs onany of the Cosworth engines.Now Costin would clockout of his job at Lotusand use his off time toengineer over at Cosworth.He did this for the firstfour years of the company.It's just like how I clock out of Donut,and then I go work onmy own YouTube channel,Babies Reacting to Surgery.Click that bell so you don't missany babies reacting to any surgeries.Development soon began ontheir first race engine.Duckworth had his eyeon a brand new type ofracing called Formula Junior.This was an entry level classof open wheel racing limitedto 1000 cc engines usingbasically stock engines.It was meant as a gateway to F1,and it would be the perfectproving grounds for the lads.Mike Costin and old Ducky Boy, as I liketo call him, had a working relationshipwith Ford already through Lotus.So the gents were ableto secure two Ford enginesthat were developedfor the 1959 Ford Anglia.These babies were small.I'm talking one liter small.They only made 39 buff ponies stock,but the boys tinkeredwith the cylinder headsand tested new cam shaft designs.They got the second motor,the Mark 2 up to 75 skinnyyet powerful Bronies which isnothing to shake a stick at.Then they sold that engineto Lotus who dropped itin their Super 7.It was already a stellar car,but with the new Ford Cosworth engineinside, it straight upkilled at the track.Lotus Super 7 starteddominating competitions.The Mark 3 engine wasan even more powerfulversion of the Ford Inline 4,now making 95 mid-century horses.I'm talking Eames ponies.I'm talking Frank LloydWright Clydesdales.This was the first engineCosworth made that wasn'texclusively sold to Lotus.Other race teams werelike, "Hey, what the heck?"We want one of them dagblasted engines too."And Cosworth was like,"Right on, rock and roll."The success of the new enginesmeant that Cosworth wasn'tfinancially dependent on Lotus anymore.Oh no boy, they were free.I make my own money.I buy my own clothes.I do what I want dad.Quack, quack, quack, quack.It was clear that the engineersat Cosworth could make abanger, slappin' engine.Colin Chapman new it and Ford knew it.So in 1966 Colin Chapman played matchmakerand convinced Ford to invest in Cosworth.They signed a $100,000contract that includedthe development of two different engines,the four cylinder FVA engineor Four Valve type A was basedon a Ford cross flow engine block.It feature twin overhead cams, 16 valves,Lucas Fuel Injection which sucksand Duckworth's very owncustom cylinder head.This inline four couldproduce 225 horsepowerat 9000 rpm and would go onto dominate Formula Two until 1971.It's an amazing engine.But it was just the startof what was to come.You see the FVA was just proof of conceptfor the next project, Cosworth's screamingthree liter V8 named theDFV which I assumed stoodfor damn fast vehicle, lightning.If there's one thing you need to knowabout Cosworth, it's this engine, okay.The DFV was the first enginecompletely designed by Cosworthand there was one more thingI wanted to mention about it.Oh yeah, it was the mostsuccessful F1 engine of all time.(car engine roaring)Think about that fellas and gals.That's like if I lovedsaxophone music which I do,and I loved it so much that I decidedto make my own saxophone from scratch.Then that saxophone wenton to become the best saxophone ever madeand Bill Clinton would play my saxophoneat the Hollywood Bowl.And everybody would clapand nobody would laugh.The double four valve engine,like its name implies, wasbasically two of the four cylinderFVA engines duct taped together.Cosworth produced thefully custom cylinderblocks and crank case in-house.The three liter V8 made 410 buff HRSPRS.At the time, one of theirbiggest competitors,the Ferrari 312 made thesame amount of power,but they used four more cylinders.The first time the engine was used wasin the 1967 Formula 1 Dutch Grand Prix.Colin Chapman threw it in his Lotus 49,and driver Jim Clark took first.That's not bad.That's the first friggin'time that they used it.So Formula 1 is very strict about who getsto use their footage, butwe were granted rare accessto a piece of film ofthe Dutch Grand Prix.Please.(host imitating race cars)And down the stretch they come.I'm gonna win.(host imitating race cars)And Cosworth has done it.They've crossed the finish lineand (mumbles) the checkered flag.First time out, and they win it.They win it all.Oh, this footage is so authentic.What an amazing race.What authentic footage.Here they are on the podium.It looks so real, thatfeel of authenticity.And look at them spray the stuff.He's kissing his girlfriend.She's Cindy Crawford.I can't believe this is real footage.Oh, he jumps over thosecrocodiles like a mad man.Oh, there's the pirates.Oh no, the pirates have showed up.The pirates have showed upand they're swashbuckling.Colin Chapman swings downon a rope like a Robin Hoodand cuts all their heads off.Not only a great engineerbut a great swordsmanand a great statesman andgreat, great authentic,not at all faked footage.(men and women laughing behind-the-scens)Cosworth actually made a wholeF1 car on their own one year,but it never raced.It was way ahead of its time.It had a four wheel drive system cooked upby Duckworth himself, amagnesium block DFV engineand was built using a lightweightwood and aluminum composite.It was supposed to compete atthe 1969 British Grand Prix.But it was silently withdrawn,because it was too good.We'll never know.Duckster's laboratory continuedto develop race enginesbut on the commercial side,that's the stuff we can buy,another project wasbeginning to take shape.Ford of Europe wasworking on a replacementfor the hugely successfulsmall family car, the Anglia.Cosworth had a ton of experience messingwith the Anglia's engines,so they were the natural choiceto build an upgraded versionfor its successor, the Escort.The BDA or Belt Drive type Aengine was a 1600 cc inlinefour with duel overheadcams and 16 valves.It was developed for homologation purposesfor a little thing called rally racing.Maybe you've heard of it.We talk about it a little bit.(car engine roaring)The first car to use the BDA engine wasthe Ford Escort RS1600.This thing racked up tons of rally wins.It made a 120 horsepowerwhich was unheard of fora small car at the time.By 1969 Ford and Cosworthwere basically BFF's.They raced each other.They did business together.They picked each otherup from the airport,because that's what's friends do Nolan.Ford would never makeCosworth take an Uberfrom the airport, becausethey have a weird rash.The RS1600's more athleticbrother, the RS2000.Bought it in 1973.It was slightly more powerfuland refined than the RS1600with a zero to the 60 time of nine secondsand a top speed of 110.(car engine roaring)This car also rackedup a ton of rally wins.If you wanna know more aboutall these dang Escorts,you can check out the Up to Speed episode,you guessed it, on the Escort.(car engine roaring)We could go on and onabout Cosworth's race wins,but that would be a very long video.And I have to go poo-pooh.So I'm gonna hurry things up.My apologies.In 1975, Cosworth took theiralready very successfulDFV engine and slappedon a friggin' turbo.(car engine roaring)It now made 840 buffyet intelligent horses.The DFX quickly becamethe standard Indy carengine, dethroning thedominant Offenhauser,aka the Offy engine.Now success was not alwaysguaranteed for Cosworth.In 1975, Chevrolet produced5,000 Cosworth edition Vegas.But GM's general manager at the time,a little dude namedJohn Delorean, aka, Docfrom Back to the Future, wantedto improve performanceof the Vega followingin the onset of emission standards.So he sent an engine designer to Englandto scope Cosworth outin hopes that they would designa cylinder head for Chevy.Cosworth agreed.The next five years werespent troubleshooting engineproblems, going backand forth with the EPA,and worst of all taking away horsepowerto meet emission standards.When the Cosworth Vega madeit off the production line,it absolutely 100% failed to deliver.It was originally meantto have 170 HRSPRS,but the final product only made about 110,and it was almost double theprice of a base model Vega.They only sold about 3,500 of the expected5,000 hand-built Cosworth Vegas.And the rest were scraped.I think that it looks pretty sick.And they did make a 290HRSPR version for the track,but it wasn't enoughto sell any road cars.Now this was the first timeCosworth ever had theirname on a production vehicle.And unfortunately, itwas a monumental stinker.Their production models would haveto be better in the future ortheir reputation would suffer.But while the Vega wasstruggling, Cosworth poweredcars were slaying rallyraces around the world.(car engine roaring)The new RS1800 debuted witha second gen Escort in 1975.This was when we firststarted seeing featureson their rally cars that arenow classic Cosworth style.And I'm talking big old wild wheel archesand signature fitman of high beamson the front for night rallying.The RS1800 had an updatedversion of a twin cam enginedesign for the RS1600.A new engine rules meant theycould bore it out and get...This is getting ridiculous.I have to do something.I must find him.(somber music)(siren blaring)Where are you?(man crying)See if I get any calls.The updated inline fourmade 245 herstey hogsand was now made into astraight-cut five-speed ZF gearbox.With the RS1800 the Cosworth rallyteam was basically unstoppable.(car engine roaring)But do you think Cosworthkicked back and got cozy?If you said yes, you'rewrong, 'cause they didn't.They constantly strived tomake their engines better,more powerful, and moredominant than the competition.With production ramping upfor a third generation Escort in 1980and rally racing gainingsteam, Cosworth found themselfon the precipice of something great.This decade would producesome of the most iconicCosworth powered cars ever.Ford had won the WorldRally Championship in 1979with a Cosworth powered RS1800.But the FIA was about tolaunch a new rally class.They had way fewerrestrictions than Group Aor as like to call it Group Baby.Enter Group B.(car engine roaring)Group B rules were veryrelaxed when it cameto engine size, car weight,and constraints on technology.Ford did one of those big,oh no, we're gonna needto make our cars better.So the boys at Cosworth tooka variant of their twin cam inline fourand slapped a big ole turbo boy on it.(host screams)A 1.8 liter BDT engine produced justover 200 horsepowerfor the street version.But the race version, therace version, could make upto 450 buff mother fathers.Ford put a 300 horsepowerversion of the BDTin their brand new third-gen Escort.And the result was the RS1700T.(car engine roaring)Development of this car turned outto be a huge pain in the arse,'cause the third-gen Escort was builton a front-wheel drive platformwhich wouldn't be thebest for rally driving.Then freakin' Audi came out of nowherewith the Quattro all wheel drive systemand started slaying the competition.Just kick 'em right in the nards.Ford tried to scramble tomake the 1700T all wheel drivebut ended up scraping theentire project in frustrationbefore it could ever officially race.They decided that the only way to competewith the all-wheel driveAudis and Peugeots wasto build an all-wheel drivecar from the ground up.Ford built the chassis.Ghia designed the body.And Reliant built the shell.It was like a group projectand everyone did their part.And guess what?They all got an A.The result was the RS200.(car engine roaring)Mounted in the middle ofthis tiny, awesome lookingcar was the Cosworth BDT engine,the turbocharged four banger was now tunedto make 250 HRSPR on the streetwith race versions all the way upto 444 buff horses at 8,000 rpmand 360 tweeerk bois.This is one of the coolestCosworth cars ever made.Kent Block has one.He won't shut-up about it.Every time we have a frickin'internet car guy potluckhe's like, "Hey guys,you seen my Cosworth?"We're like.- "Ken,yes we've seen it."- And he's like, "Do you like it?"We're like.- "Yes Ken we like it."- He is cool though, cooler than me.But it didn't do great in competition.It was too heavy to competewith the Italian and French cars.And one time it flew off ofroad and killed three people.Group B is crazy.And if you wanna learn moreabout it watch the Up to Speed on it.For now, Colby show 'emhow crazy Group B is.(car engine roaring)Cosworth as a company neverstopped being in demand.They were constantly approachedto work with other manufacturersto develop high performancehomologation engines.Mercedes saw the valuein their tuning skillsand commissioned the companyto produce some homologationversions of their entry level sedan.Enter the Mercedes Benz190E 2.3, 16 Cosworth.Add it to the list.The rally versions were insanely powerful.And the street versions are literallyone of my favoritelooking cars of all time.Cosworth also workedwith Opel helping designa long throw diesel crank enginefor a rally version of the Opel Mantaand Ascona, as well as atwo liter 16 valve enginefor the Astra and Calibra.Later on Cosworth tuned aturbocharged 2.7 liter V6for the B5 Audi RS4 which made 381 HRSPRSand had a zero to 60 time ofless than 5 frickin' seconds.If I could have a B5 RS4 Iwould probably do anything.In the early 1980's Fordteamed up with Cosworthto work on a brand new Group A project.This time it was for therear-wheel drive Ford Sierra.They needed 5,000 engines tomeet the homologation minimumand asked if Cosworthcould bring the power upto 180 HRSPRS for the street version.Cosworth agreed, but under two conditions.Number one, the street engines hadto be at least 200 horsepowerand Ford had to not by five,but they had to buy 15,000 of them.And in 1986 the SierraRS Cosworth debuted.Add it to the list.(car engine roaring)It had a turbocharged twoliter YBB engine derivedfrom the Pinto with customCosworth cylinder heads,a Borg Warner T5 gearbox,and a massive whale tail, swallow tail.Let me know in the commentswhat you call this wing.This is the firstcar that people startedcalling the Cossie.The YBB engine made 240horses for the street versionand more than double that for the track.A select 500 of theSierra coupes were sentto the Aston Martin plant in Tickfordto get the special treatment.What do I mean by special treatment?Boy I'm glad you asked.These Sierras got a bigger turbo charger,better fuel system, a frickin' arrow kit.They lowered the suspension.And most importantly, they got discreetdecals that read RS500.So if you looked closely, you could tell.While the street versioncan make 224 buff horses,the track version made five hunna.(car engine roaring)The RS500s dominated touring car racingfrom 1987 to 1992, winningchampionship after championshipafter championship after championshipafter championship all over the world.And towards the end of its run,track versions of the twoliter engines were makingup to 680 horsepower.The only thing that could challengethe RS500 was the R32 Skyline.And that's friggin' Skyline.The Sierra Cosworths were doing greatin Group A rally racing.But the platform was about to transitioninto being a front-wheel drive car,and the engineers at Fordof Europe had a little idea.Let's take the YBB engineand put it into a smallerall-wheel drive car.YBB?More like, why not BB.Enter the Ford Escort RS Cosworth,one of the sickest hatchbacks ever made.Add it to the list.(car engine roaring)This Cossie had a bodydesigned by Karmann in Germany.It had a wing like the Sierra'sand significant aerodynamic upgradeson the rest of the body.The adjustable frontsplitter made the Escort RSthe first production carthat could produce downforceon the rear and the front.It had a big old turbo witha big violent entry that cameon around 3,500 rpm.(car engine roaring)Just like a Group B car.But most importantly the productioninline four engine sent 224 horsesand 224 tuerks to all four wheelswhich makes it a perfect horse port.(horn blows)Guys we did it.(man claps)Nowadays Cosworth is stillbased out of Northampton.And they're still lowkey upgrading engines.You can get a Cosworth tune-upfor your AE86 that buffshorsepower up to 280.Add it to the list.They even made a limited runof Subaru Impreza Cosworths.Add it to the list.The new Honda NSX hasan engine that was partiallydesigned by Cosworth.This one does not get added to the list.They totally did it wrong.Their inspiration was alike a luxury muscle car.You don't design.They've got a rich, crazy history.They've made some of thecoolest cars in the world.And they're still innovating.They've made huge leaps inhybridization, connectivity,and the future of propulsion.And they're still collaborating.The Aston Martin Valkyrie,one of the most intenserace car looking streetcars ever, has a 6.5 liternaturally aspiratedCosworth V12 under the hood.With 1,130 buff Cossie horseson tap, it's clear thatCosworth isn't slowingdown any time soon.Where are you?(somber music)(man crying)I love you.