The Donor
You have various options open to you. Lack of space may prevent you from stripping down a car.
New regulations are making it increasingly difficult to rid yourself of the remaining shell. However the bonus here is that the cars are becoming cheaper and you can cut your donor up to transport it to a scrap dealer.
Other alternatives are to buy a Donor Package. this is all the parts you need already stripped from the Sierra. JBA does such a package Email them for a price.
Another Donor Package specialist is KitFit who supply reconditioned parts for kit car builders, telephone contact number is 01636-893-453. Another source is your local vehicle dismantler, but be wary of buying a written off vehicle, always ask for the log book, see below.

New Regulations have come into force 07-04-2003 regarding cars that have been written off by the insurance companies. This is crime prevention scheme against car thieves "ringing" stolen vehicles.
This can pose problems for anyone building or refurbishing a kit. 
If a kit uses a part from a written off vehicle e.g. Sierra rear sub frame, then it may be subject to a VIC Check at a goods vehicle test station or other government appointed station arranged by your local Vehicle Inspectorate. This could happen when you come to register the kit after it has passed it's SVA test. Fees apply, More Info. 

The donor car you need is the Ford Sierra saloon. 
Remember that the Estate versions is not suitable as a donor nor are 4 X 4 Saloon Configurations.
The engine size is up to your own preferences, various Ford engines, Rover V8 and Fiat twin cam have all been fitted. In fact JBA make a special chassis for the Rover V8 engine.

Don't just run out and buy any Ford Sierra, but go for one fitted with the choice of engine you have in mind. It is a very good idea to register the donor car in your own name, this helps with the registration procedure once your kit is built. Remember to complete the SORN details, so that you do not become liable for Road Tax.

If you are using an engine which is not from the donor car, then you will have to supply written conformation to your SVA Test Station as to its age, when it was first fitted into a vehicle from Ford or other manufacturers Rover etc.
 

The components needed are

• The whole back end, except the shock absorbers.
• Remember the Bump stops.
• Final Drive Assembly, diff including IR Suspension.
• The engine complete with starter, alternator, distributor, carb etc. engine mounts and exhaust manifold. 
• All the electrical wiring and engine management system wiring on an EFI engine.
• Side Flashers.
• Gearbox plus mountings and gear lever and all ancillaries.
• Exhaust System (can be modified) Plus Downpipe.
• Whole front end
• You do not need the Mac Pherson struts.
• Steering rack, steering shaft, steering wheel and lighting stocks and cowling, anti roll bar etc.
• All brake parts servo etc discs, drums, brake balance valve.
• Wheels necessary for moving chassis around, even if you are buying new ones.
• Clutch and accelerator cables.
• Pedal Box including Pedals, Clutch, Brake, Accelerator.
• Also label and save the wiring loom if you are going to use part of it later, as you do not need it all, remember the reversing lamp cable on gearbox.
• Plus electric radiator fan if fitted and Fuse box.
• Battery and Coil.
• Interior door lock handles and connecting rods, you may want to use them.
• Centre Console you may or may not want to use it.
• Keep the radiator and hoses plus heater hoses, use radiator as part exchange.
• Bonnet Stay use this to make stays for the Falcon.
• VIN Plate or details from it. Handy if you have to order new cables etc.

Some builders use the original Sierra instruments etc. rather than individual units and blend them in behind their wooden dashboard.

If possible try driving the Sierra around for a while, to test it out, to ascertain it's mechanical condition before you strip it down. Remember that the car must be legal for the road, in order to do this.

Cleaning Donor Parts

Once you have stripped all the parts including engine & gearbox you will have to use a degreaser, to clean the parts. Remember to block off all entry holes into the engine. 
I used shrink rap and polythene bags held on with masking tape and left the old spark plugs in place.

You can buy degreasing agents from Halfords, products such as "Gunk" is a good one, this can be brushed or sprayed on, then leave it a while to get to work, before washing off with water. If you have one of these Power Washers use this to wash off the Gunk.

Next is to use various sizes of wire cup brushes on an electric drill and a wire hand brush to clean up and de-rust the front & rear assemblies. Alternatively you can have these parts sand blasted, which will produce far better results.
These were then painted with undercoat and finally with black enamel.
Many builders have these parts Powder coated.

Recondition

It is advisable to refurbished all the brake parts with new components. If the engine is sound, always renew the cambelt or timing chain along with the fan belt. clutch plate & thrust bearing. 
You may also want to fit a new alternator and starter motor. For anybody living in central Scotland I would recommend Shandon Electrical at Bellshill Industrial Estate. Tel: 01698 843602 for alternators and starter motors. For other areas visit your local motor factor. The steering rack is another item that you should consider renewing, cost is about £30.00p from a motor factor. 
You will usually find motor factors in an industrial estate near you.
More information about the Donor strip down below.

Save on Parts

If the firm you are employed with has their own vehicle fleet and the fleet is maintained in your company's workshops. Ask your fleet engineer or mechanic to order your parts. He will get them cheaper than your company does. 
Here is how it works, your company gets a discount on the goods they buy, the more they buy the bigger the discount. The firm supplying them wants your firms business and they want to keep it. So they keep in with the mechanic, fleet engineer or stores person and allow him maximum discount on parts for his own use.

The next page deals with collecting your Kit.  

   Top Photos Courtesy Of  David Bradburn and Doug Philp.