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Mike Costin
Mike Costin
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British Grand Prix, Formula 2 Race, Silverstone July 1956. Lotus Development Director Mike Costin on left holding notes.Colin Chapman in Lotus Eleven. Chief Mechanic John Crosthwaite on right leaning on car.

Michael Charles Costin (born 10 July 1929, in Hendon) is a British engineer. Together with Keith Duckworth, he co-founded Cosworth Engineering,[1] a producer of Ford-funded and sponsored engines. Drivers including Graham Hill, Jackie Stewart, Jochen Rindt, Emerson Fittipaldi, James Hunt, Mario Andretti, Alan Jones, Nelson Piquet, and Keke Rosberg won the Formula One World Championship using Cosworth DFV engines during the 1960s, 1970s and 1980s.[2]

He was educated at Salvatorian College in Wealdstone and then apprenticed at De Havilland. In 1953 he started at Lotus, initially helping out on a part-time basis. Keith Duckworth joined Lotus in 1957 and they founded Cosworth Engineering in 1958. He later described himself as having "studied for 40 years at the University of Duckworth".[1]

In recent years he has been a consultant to the revived Triumph motorbike company.[1]

Mike Costin is the younger brother of Frank Costin, an aerodynamics and race car designer for Lotus, Lister and Maserati, and co-founder of Marcos Cars.

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from Grokipedia
Michael Charles Costin (born 10 July 1929) is a British engineer best known as the co-founder of Engineering, a company renowned for developing high-performance racing engines that revolutionized and . Costin began his career in aeronautical engineering after completing an apprenticeship at , where he worked as a design draughtsman on projects including test rigs for the airliner. In 1953, he joined as one of its earliest employees, serving as a key designer and developer under , contributing to the evolution of Lotus vehicles from the mid-1950s onward. In 1958, while still at Lotus, Costin co-founded Engineering with fellow engineer in a small garage in , initially focusing on tuning Ford engines for racing applications. He transitioned to full-time work at in 1962, becoming its chairman and guiding the company's growth into a global leader in technology. Under Costin's leadership, produced landmark engines such as the tuned Ford 105E for the Lotus 18 in the early 1960s and the iconic DFV (Double Four Valve) V8, which debuted in 1967 and powered Lotus to victory in its first race at the , eventually securing over 150 Grand Prix wins, 12 drivers' championships, and 10 constructors' titles. Later innovations included the Sierra engine in 1986, which delivered reliable 204 horsepower in a limited production run of over 5,000 units. Costin also had a brief racing career, including one Formula 2 start in 1967, and remained involved in testing Cosworth prototypes, such as achieving 175 mph in the DFV at Snetterton. He retired as Cosworth chairman in 1990 but continued as a consultant, maintaining his passion for and into his later years.

Early Life

Childhood and Influences

Michael Charles Costin was born on 10 July 1929 in , , as the youngest of four children in a family that fostered an environment conducive to technical interests. From an early age, Costin exhibited a strong passion for aeroplanes, a fascination deeply influenced by his eldest brother, Frank Costin, who was nine years his senior and had embarked on a career in . Frank's work, including addressing aerodynamic challenges on projects like the twin-boom jet fighter, served as a key inspiration, drawing the young Mike into the world of flight and mechanical design. This early enthusiasm propelled Costin to leave school at age 15 in 1944, amid the final years of , to pursue hands-on involvement in engineering rather than continued formal schooling. The wartime context heightened the allure of , aligning his personal interests with the era's technological demands and setting the foundation for his lifelong career in precision engineering.

Education and Initial Training

Mike Costin was educated at Salvatorian College in Harrow Weald before leaving school at age 15 without pursuing higher academic education, reflecting his early disinterest in formal studies but strong practical aptitude. He began a five-year trade apprenticeship at the around 1944, following his childhood passion for aeroplanes. This program provided foundational training in aeronautical engineering during the post-World War II recovery period, emphasizing hands-on mechanical work and practical problem-solving in a resource-constrained environment. After two years, Costin's demonstrated practical intelligence led De Havilland to upgrade him from a basic trade role to an engineering apprentice, where he focused on core skills such as designing test rigs for aircraft components, including those for the Comet airliner. This hands-on experience honed his abilities in aerodynamics and precision engineering, fostering self-taught expertise through real-world application rather than theoretical university study. Upon completing the apprenticeship around 1949, he briefly served National Service in the Royal Air Force before returning to De Havilland, solidifying his foundational engineering competencies without obtaining a formal degree.

Early Career

Work in Aviation

Following his apprenticeship and National Service in the Royal Air Force, Mike Costin returned to the in late 1952, taking up a role in the drawing office focused on designing test rigs for aircraft components. This work centered on creating specialized equipment to evaluate the performance and durability of aviation hardware during the post-World War II era of rapid technological advancement. A key project involved developing test rigs for the , the world's first commercial jet airliner, which entered service in 1952 and represented a milestone in high-speed flight . Costin's designs emphasized precision and reliability, incorporating aerodynamic principles to simulate real-world stresses on components such as engines and structural elements. Through these efforts, he honed expertise in high-precision techniques essential for ensuring the safety and efficiency of advanced aircraft systems. His time in aviation provided a strong foundation in rigorous testing and materials handling that later influenced his contributions to other fields.

Transition to Automotive Engineering

By the early 1950s, Mike Costin, having established himself in aeronautical engineering at , grew increasingly drawn to the dynamism of motorsport amid perceived constraints in opportunities. Influenced by his participation in the 750 Motor Club, where he encountered , Costin sought greater excitement in road and racing car development, marking a pivotal shift around 1953. Costin began his involvement in on a part-time basis in January 1953, balancing his full-time role at with evening work focused on tuning and design, motivated by the dynamic challenges of automotive engineering and faster-paced development cycles. He contributed to modifications, such as lining down a 1172cc to 1098cc for versatility across racing classes, and developed custom tooling to reshape tappets for enhanced performance. These efforts represented his initial application of skills to automotive contexts, often extending late into the night after long days in . In parallel, Costin engaged in early collaborations with small engineering operations, leveraging his aviation background to adapt aerodynamic principles to car design. Notably, in , he worked with his brother Frank Costin, an aircraft designer, on streamlining prototypes using balsa wood and plasticine models to optimize for low-drag body shapes. Driven by a personal passion for hands-on innovation in the fast-evolving field of motorsport—contrasting the more rigid sector—Costin committed fully to by January 1955, leaving to pursue this path exclusively.

Lotus Period

Joining the Team

Mike Costin joined Lotus Cars in January 1953 on a part-time basis while continuing his day job as an engineer at de Havilland Aircraft Company. He was recruited by founder Colin Chapman following Chapman's fallout with his previous collaborators, the Allen brothers, and after the two men met through mutual contacts in the 750 Motor Club. Chapman sought Costin's engineering expertise to support the development of early Lotus prototypes, recognizing his skills in aircraft design and enthusiasm for motorsport. Costin's initial responsibilities involved assisting with workshop operations at Lotus's facility, where he would commute after his shifts at to work late into the night. This included assembling kits and performing basic engine modifications to enhance performance for racing applications. As one of only two core team members alongside Chapman, Costin quickly became integral to the fledgling operation, which operated as a small-scale enterprise focused on kit cars and special builds. By early 1955, the growing success of Lotus models and increasing customer demand prompted Costin to transition to full-time employment, leaving on January 1 at a salary of £15 per week. He was rapidly integrated as Chapman's deputy, effectively serving as the and overseeing management and further car development tasks. This role solidified his position as a key figure in Lotus's early expansion, contributing to the company's shift from a part-time venture to a dedicated outfit.

Key Contributions at Lotus

During his tenure at Lotus from 1955 to 1958, Mike Costin served as technical director under Colin Chapman, effectively acting as the company's number two and overseeing the development of prototypes at the Hornsey facility. In this role, he managed key modifications to chassis designs to accommodate various engines, ensuring the adaptability of racing prototypes while production vehicles were handled by engineer Nobby Clark. Costin's leadership in prototype work positioned him as Chapman's right-hand man, contributing to the technical evolution of Lotus vehicles during a formative period for the company. Costin made significant engineering contributions to specific Lotus models, including the development of the Lotus 16 single-seater for Formula 1 competition. He also innovated on engine performance through camshaft modifications, such as designing specialized tooling and reshaping tappets to alter action on the Lotus Mk6, which improved power delivery and handling in 1100cc class club races. Additionally, Costin collaborated with his brother Frank, an expert, on suspension and bodywork enhancements; for instance, they refined the Lotus Mk8 with a low, wide front profile and fin-shaped rear wings to optimize airflow and stability, enhancing overall race performance. By 1958, Costin balanced his demanding professional responsibilities with family life, having married and fathered three children, which influenced his decision to renew a three-year contract with Lotus for financial stability. This period underscored his ability to integrate intense engineering demands with personal commitments, solidifying his foundational impact on Lotus's technical advancements.

Cosworth Founding

Partnership with Keith Duckworth

Mike Costin and first met at Lotus in 1956, when Duckworth, then a 23-year-old engineering student, undertook vacation work at the company's facility during the summer. Their initial encounters occurred amid the hectic environment of the Lotus works, where Costin, aged 27 and serving as Colin Chapman's deputy, was involved in various development projects. The two bonded over their shared passion for high-performance engines, collaborating on engine tuning and development tasks at Lotus, with Duckworth contributing to innovative designs such as the sequential gearbox while Costin focused on practical implementation and testing. Duckworth's theoretical expertise, honed through his engineering studies, complemented Costin's hands-on experience from his aeronautical engineering background at de Havilland, where he had applied aerodynamic principles to aircraft components. This synergy fostered a strong professional rapport, as they recognized the limitations of Lotus's in-house capabilities and frequently discussed the potential for an independent venture specializing in racing engines. By 1958, their conversations had evolved into action, formalizing a that leveraged Costin's practical aero-derived implementation skills and Duckworth's prowess to address the growing demand for specialized high-performance development outside of Lotus.

Establishment and Early Operations

Cosworth Engineering Ltd. was co-founded by Mike Costin and , colleagues from Lotus, on September 30, 1958, initially in a shared garage in , . The originated from their shared interest in development during time at Lotus, where they discussed establishing a specialized firm focused on motorsport. The company started as a modest operation, equipped with a single purchased for £600 and bolted to the garage floor, along with basic machinery such as a and milling machine; these tools were adapted from limited resources, including second-hand items sourced affordably to support initial testing. Initial funding came primarily from Duckworth's personal savings, supplemented by small contracts for preparing , allowing the firm to sustain operations without external investment in its formative months. Early efforts centered on tuning engines for performance applications, beginning with modifications to Coventry Climax units for Elva sports cars and expanding to Ford powerplants, including the Anglia 105E for Lotus Formula Junior projects. By 1959–1960, the firm's Mk1 project involved enhancing the Ford Anglia 105E engine through improved crankshafts, connecting rods, pistons, and cam profiles, achieving initial outputs of 75-85 bhp from the 997 cc unit. Costin transitioned to full-time involvement with in August 1962, following the end of his contract at Lotus, enabling a stronger emphasis on these Ford modifications and broader initiatives during the company's early growth phase. The operation relocated several times in its first years—from Kensington to a dilapidated stable in Friern Barnet, then to in 1960—before establishing a more permanent base in by 1964 to be close to suppliers and expand facilities.

Cosworth Innovations

Development of Initial Engines

In the formative years of Cosworth, founded in 1958 by and , the company focused on tuning and modifying production Ford engines to meet the demands of club-level and national racing, leveraging Costin's expertise in engine development from his time at Lotus. These initial projects emphasized incremental power gains and improved reliability through lightweight components and optimized porting, often starting with the Ford 105E Anglia block. By adapting these engines for categories, Cosworth achieved early successes, such as powering Lotus 18 chassis to multiple class victories in 1960-1961 events, where modified units delivered around 75-90 from 997cc displacements, a significant uplift from stock outputs of about 40 . The SCA engine marked Cosworth's first fully in-house design effort, introduced in 1964 specifically for the new 1.0-liter Formula 2 regulations. Built on a Ford 105E block with a bespoke aluminum featuring a single overhead and reverse-flow ports, the 997cc SCA produced 115-140 depending on tuning, with versions reaching the higher end by 1965. This engine debuted successfully at the on April 5, 1964, where secured victory in a Lotus 32, contributing to the SCA's dominance in F2 with an 81% win rate across 1964-1965 internationals. Parallel to the SCA, Cosworth continued refining Ford-based units for Lotus and independent teams, particularly the Mk VIII variant for the Lotus Seven, which used a 1,498cc displacement to yield 90 bhp through enhanced breathing and balancing. These modifications prioritized durability for endurance events, enabling consistent performances in national sprints and hillclimbs, though production was limited to small batches due to resource constraints. Costin oversaw much of the testing, ensuring the engines balanced power with everyday usability for club racers. For smaller displacement classes, the MAE (Modified Anglia Engine) emerged in 1965 as a cost-effective solution for Formula 3, utilizing the Ford 105E block enlarged to 997cc and fitted with a single downdraft carburetor for 100-110 bhp output. Designed for affordability, it was often supplied as a tuning kit to meet surging demand, allowing teams to assemble units in-house and dominating F3 grids from 1965 to 1968 with multiple national championships. Despite these innovations, Cosworth's early operations faced significant hurdles, including operating from a modest workshop with limited capital—initial investments like a £600 strained finances—and reliance on manual machining for prototypes. Nevertheless, the tuned Ford engines secured numerous club and national event wins in the early 1960s, such as 47% success in races from 1960-1963, validating Costin's approach and paving the way for larger projects.

The DFV Engine and Formula 1 Dominance

In 1966, with funding from Ford amounting to £100,000, began development of the 3.0-litre V8 DFV (Double Four Valve) engine under the leadership of , with Mike Costin playing a pivotal role in translating the designs into production reality. The engine, completed in just nine months, made its operational debut in February 1967 and raced for the first time at the in June of that year, powering Jim Clark's to victory on its maiden outing. Costin oversaw the production scaling at 's facility, enabling output of over 25 engines per year by the late 1960s, while also personally testing the DFV on the track, achieving speeds of 175 mph during early runs at Snetterton. The DFV's innovative design featured a lightweight all-aluminum block and heads, which contributed to its compact dimensions and reduced overall vehicle weight compared to contemporary rivals. Its was engineered for high-revving performance, safely capable of up to 11,500 rpm initially, with later evolutions reaching 12,000 rpm, though the standard was set at 9,000 rpm where it produced around 400 horsepower. A key advancement was the engine-as-stressed-member concept, originally conceived by Duckworth and implemented by Costin during production; this allowed the DFV to serve as a structural element of the , bolted directly to the with just four attachments and incorporating a quill hub to manage torsional vibrations up to 4,000 pounds in heavy cornering. This integration revolutionized Formula 1 design by eliminating the need for a separate rear subframe, enhancing rigidity and for teams like Lotus. The DFV propelled Lotus and subsequent customer teams such as Tyrrell, , and Williams to unparalleled dominance in Formula 1, securing 155 Grand Prix victories between 1967 and its final win in 1983. It powered 12 Drivers' World Championships and 10 Constructors' titles over its primary competitive lifespan through the 1970s, including every race win in both the 1969 and 1973 seasons. In 1967 alone, the engine helped Lotus claim four victories, establishing Ford-Cosworth as the benchmark for reliability and performance in the 3.0-litre era.

Expansion into Other Racing Series

Following the success of the DFV engine in Formula 1, Cosworth adapted its technology for other racing series, notably developing the turbocharged DFX variant for competition. Introduced in 1976, the 2.65-liter V8 DFX powered vehicles to dominance in the USAC and championships from 1977 to 1987, securing all titles during that period. It also achieved ten consecutive victories at the from 1978 to 1987, establishing Cosworth as a powerhouse in American open-wheel racing. Cosworth extended its engine expertise to endurance racing, particularly at Le Mans, where DFV derivatives propelled prototypes to multiple successes in the 1970s and 1980s. The DFV itself powered the Gulf-Mirage GR8 to overall victory in 1975, with additional podium finishes that year, while Rondeau entries using the engine claimed class wins and top-10 results from 1977 to 1981, including the outright win in 1980. The company also developed turbocharged engines for rally cars, such as the YBT 2.0-liter unit in the Ford Escort RS Cosworth, which competed in the World Rally Championship from 1993 to 1998 and secured numerous stage victories. Although Cosworth's direct involvement in NASCAR was limited until the late 1990s, its high-performance V8 designs influenced broader American stock car development through Ford partnerships. In parallel, entered the production car market by supplying turbocharged engines for high-performance road models, adapting racing-derived components for specials. The YB 1.993-liter turbo four-cylinder, producing 224 horsepower in road form, powered the and its RS500 variant from 1986, with 500 RS500 units built in 1987 to meet Group A racing requirements; these engines enabled dominance in series like the . also provided 2.3-liter and 2.5-liter turbo engines for the 190E in the 1980s, supporting its DTM campaign. Later collaborations included special editions like the STI CS400 in 2007, which featured a -modified flat-four exceeding 400 horsepower. By the 1980s, leveraged its racing innovations for diversification into non-automotive sectors, including , components, and defense applications. This expansion applied high-precision engineering from —such as and turbocharging—to projects like naval systems and UAV technologies, enhancing the company's resilience beyond racing fluctuations.

Personal Racing Involvement

Early Racing Experiences

Mike Costin's entry into began in the early 1950s through his involvement with the 750 Motor Club, where he participated in informal pub meetings and club events that sparked his interest in racing and tuning. These gatherings introduced him to like-minded enthusiasts, including , and provided an outlet to experiment with vehicle modifications on a grassroots level. He started racing with modified road cars, applying his engineering skills from to tune engines and suspensions for improved performance in local competitions. By the mid-1950s, Costin shifted to competing in club events and sprints using early Lotus prototypes, which allowed him to test his tuning modifications in practical settings. He assembled a Lotus Mk6 , collaborating with on its construction, and modified its Ford 100E engine by linering it down from 1172cc to 1098cc to qualify for multiple classes. Costin drove this Mk6 in national races, such as 1172 Formula events, where it delivered quick lap times and provided valuable on-track feedback that informed his subsequent engineering designs at Lotus. Costin's racing remained focused on development and testing rather than pure competition. This included Formula 2 outings to evaluate engines, such as 4th place in the 1964 Vanwall Trophy at Snetterton in a BT10 with the SCA engine, pole position at the 1965 BARC 200 at (race cancelled due to waterlogged track), and an appearance on March 27, 1967, at . Driving a -powered BT10, he entered the European Formula 2 Championship opener primarily to evaluate the new 1.6-litre FVA engine under race conditions. These outings underscored his role in using personal racing to refine engine performance ahead of broader applications.

Notable Achievements and Records

Mike Costin's personal racing career in the and 1960s featured several national-level outings, primarily with Lotus and machinery, where he achieved notable results as a driver. In December 1958, he secured third place in the BRSCC GT event driving a for . His most prominent success came in 1960 during a race at Oulton Park, where Costin claimed , set the fastest lap, and won the event in a Lotus 18 powered by a Ford engine. Later that year, he recorded additional participations, contributing to his single overall victory and multiple class podium finishes across national series. Costin also competed in Formula 2 events during the mid-1960s using a BT10 fitted with engines, including a in 1965 and races in 1964 and 1967, though without further wins. These outings allowed him to set lap records at British circuits such as Oulton Park, leveraging the performance of -tuned powerplants. In addition to sprint races, Costin participated in endurance-style sports car events, such as the 1958 meeting, where his driving provided practical insights into vehicle and engine durability under prolonged conditions. He retired from active in the late 1960s to concentrate on managing , amassing a career tally that included one outright win, several podiums, and multiple class victories in national competitions.

Leadership and Later Career

Executive Roles at Cosworth

In 1987, Mike Costin was appointed of , taking on leadership during a period of expansion complicated by the company's recent acquisition by United Engineering Industries in 1980 and ongoing financial pressures from shifting motorsport economics. Under his guidance, pursued growth in engine production for both racing and road applications, leveraging its technical expertise to navigate strains exacerbated by the high costs of Formula 1 development and broader industry recessions in the late 1980s. Following Keith Duckworth's retirement, Costin assumed the role of chairman in 1988, steering the company's strategic direction through to his own departure in 1990. In this capacity, he managed key partnerships, including the longstanding collaboration with Ford that supported engine supplies to international Formula 1 teams and production projects like the Sierra RS , ensuring Cosworth maintained its edge in high-performance engineering amid competitive pressures from manufacturer-backed rivals. Costin also oversaw efforts to diversify beyond pure racing into non-racing sectors, such as road car powertrains and , which included initiatives like the establishment of an electronics division and engine development for the 190E in DTM racing. These moves stabilized the firm during economic uncertainties, including ownership transitions and market volatility, by broadening revenue streams while preserving Cosworth's reputation for innovation.

Retirement and Consulting Work

Mike Costin retired from his role as chairman of in 1990, after more than 30 years with the company since its founding in , at the age of 61. In the years following his retirement, Costin served as an for the revived Triumph motorcycles during the 1990s. He also provided expertise to various automotive firms on engine design and testing, remaining in demand as a and businessman. Additionally, Costin maintained involvement in industry events, sharing insights on historical developments in motorsport engineering through interviews and discussions, including a visit to in 2022.

Legacy and Personal Life

Impact on Motorsport

Mike Costin co-founded in 1958 with , establishing a that became synonymous with high-performance engines and profoundly shaped the landscape of international . Under their leadership, Cosworth engines powered a significant portion of Formula 1 grids, particularly in the 1970s when the DFV unit equipped nearly the entire field at times due to its reliability, affordability, and performance advantages. This dominance extended beyond F1, influencing global standards through engines that emphasized and power output, setting benchmarks for efficiency and speed in professional series worldwide. Costin's contributions enabled to secure 10 Formula 1 Constructors' Championships and 12 Drivers' Championships, alongside 176 Grand Prix victories in F1 alone. Across various disciplines, including and endurance racing, Cosworth engines amassed hundreds of race wins, with the DFV variant alone claiming 155 triumphs between 1967 and 1983. These achievements underscored Costin's role in transforming engine design, particularly through the development of the DFV, a lightweight, high-revving V8 that revolutionized power delivery in open-wheel racing. Costin pioneered innovations in high-revving V8 architectures, such as the DFV's narrow-angle design with four valves per cylinder, which allowed rev limits exceeding 11,000 rpm and influenced subsequent engine philosophies in both Formula 1 and . This approach carried forward to Cosworth's DFX engine for , a turbocharged V8 that dominated the category in the 1970s and 1980s, winning 10 consecutive Indianapolis 500s from 1978 to 1987 and establishing standards for high-revving, durable powerplants that echoed in modern hybrid-era designs. His legacy elevated motorsport's technical standards, fostering advancements in piston technology, , and overall performance that continue to inform contemporary racing engine development. Costin's impact has been recognized through his induction into the Motor Sport Hall of Fame in 2018, highlighting his excellence and the enduring influence of on the sport.

Post-Retirement Activities and Interests

After retiring from his executive roles at in 1990, Mike Costin co-founded and co-owns a marketing company with his wife, Mary, which has operated successfully since the . This venture reflects his continued engagement in business beyond , leveraging his extensive industry connections. In parallel, Costin has pursued creative outlets in the automotive field, working as a , blogger, and contributing articles to magazines such as Motor Sport. Costin's lifelong passion for , rooted in his early career at , remains a central interest, particularly through . He has been an active glider pilot for decades, competing in national events across the . As of 2025, at age 96, he continues to participate in competitions, including the UK Mountain Soaring Championship and the Hus Bos Challenge Cup, often flying in a two-seater DG 1000T glider. On a personal note, Costin has been married to Mary since before 1958 and they have three children. The couple resides in the , where Costin occasionally attends motorsport events to stay connected to the community he helped shape.

References

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