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DP Seals has developed an advanced seal solution for the Ford-Cosworth Duratec ‘R’ engine, the powerhouse behind the success of the Ford Martini World Rally Car. Developed in conjunction with Cosworth Racing engineers, these tailored rubber compound seals have helped ensure the Ford car’s rally success in 2001.

Rally car engine developers must operate within F.I.A. regulations that challenge technical innovation and still gain that essential competitive edge. In the 2001 version of its 2-litre Duratec ‘R’ engine, Cosworth Racing increased power output to 3% more than its predecessor, with better torque and decreased turbo lag.

“Rally engines place exceptional demands on all their components, particularly the many seals and gaskets which must perform for long periods of time in the presence of high temperatures and pressures, and aggressive fluids and atmospheres. With no out-of-the-catalogue solution available, we called on DP Seals’ specialist rubber moulding expertise to help overcome a specific seal durability issue.”
Malcolm Tyrrell, Head of WRC at Cosworth Racing

DP Seals is no stranger to innovating advanced seal solutions for high performance engines, having already provided seals for F1 and Le Mans competitors. Working alongside Cosworth engineers, DP Seals defined a special HNBR (hydrogenated nitrile) rubber formulation and developed the necessary tooling to mould the new seals, ensuring the tight tolerances demanded for the Duratec environment were met. The resulting seals have proven highly durable throughout the 2001 World Rally season.

Whereas most rubber seal and moulding companies work with a limited range of stock rubber sources, DP Seals not only designs custom mouldings to meet its clients’ needs, it also tailors the rubber compounds to meet particular combinations of performance parameters. Through its on-going research and development programme, the company continues to work with Cosworth Racing on creating custom seal solutions.

About Cosworth Racing
With experience spanning four decades, Cosworth Racing is a world leader in design, development and manufacture of ultra high performance gasoline engines for racing, rally and road car applications. Cosworth Racing provides power plant technology and design solutions for premier teams in Formula 1, World Rally, CART(USA) and Motorbike racing, as well as racing engine technology transfer to the Premier Automotive Group of Ford Motor Company. More information is available at www.cosworthracing.com.