In this paper, a novel design scheme for radar signal is proposed. It is based on a modification of Costas codes design by increasing the frequency separation of frequency hops beyond the orthogonality condition. Indeed, Costas codes are well known for their good range-doppler properties. Their orthogonality condition states that frequency separation between frequency hops should be at most equal to the inverse of bit duration of the code. Increasing frequency separation beyond this condition leads to the appearance of grating lobes near the main temporal lobe of the autocorrelation function. This paper proposes overcoming this problem using sub-pulse coding. The originality of the proposed approach consists in choosing for Costas sub-pulses other Costas codes instead of constant frequency ones in order to lower autocorrelation grating lobes that would normally appear when the orthogonality condition is not satisfied. In this paper, we show that under some conditions on Costas signal parameters in the sub-pulse, good elimination of grating lobes is achieved.