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Old 02-19-2012, 02:48 AM   #1
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Join Date: Dec 2010
Fan#: 81394
Location: Redmond, WA
What I Drive: um donated 2002 blue Focus

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RSF2000 RWD Rally Focus

So thought I would throw my build on hear hope y'all don't mind theres a few photos to start with Ill put my mission statement and an idea of the build.

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hear was my original Idea some bits have changed but the idea is the same.RWD Focus:

1 They are very plentiful there are over 2,000,000 in the us alone!
From 2000 to now they have not changed suspension framing, With a few minor
changes like in 05 they moved to ears for there front brakes. 2000 to 2004 are
showing up in our local inexpensive junk yards, where spare rack and pinions and
components are cheap and in huge numbers.

2 The cars are only falling more in price I have seen running 2000 focus's for
under 1000 and almost free if they have motor issues. Also now on CL there is two 2005
with 2.0 duratecs for 3500 obo.

3 The Duratec! a very versatile and good power plant that picking up a huge after market
fallowing thanks to open wheel and custom swaps in the UK and states.
The ford harness is flashable and easy to adapt and swap. In the states any mazda
turbo 2.3 steel crank will fit the 2.3, and they go for $300.

4 The swap parts are easy to find, such as ford explorer rear diff and t5
transmission. The explorer diff has a limited slip factory but can be upgraded with
a carbon Kevlar clutch pack and forged housing for under $300 and can
have custom preload for little extra, along with about any gear choice needed for street or rally.

5 The front and rear frame will have to be replaced and thats what I will be building
and selling The goal for the frame's cost will be $1200 for front and rear frame. There are
quite a bit more parts that it will require but this to get to a point where the focus can be
the best RWD for the buck.

6 Cost. I want to set people up with the options to have a rwd car that with have a near
perfect formula, Close ratio gear box good limited slip and with plenty of power NA or turbo.
If the budget is tight there are several stock ford transmissions like ranger or miata 6 speed.
and stock gear ratios and limited slips are not that far off from pretty damn good.

7 Repairs and spares. With the cost of diffs and t5s and duratecs people can afford
to have spares. Going home with blown motors or a dead box's would be a thing of the past
for the entry level racer.

8 Other cars This swap kit will not be just for focus it will cross in too the mazda 3,
volvo s40 60 80 and c30. It will also work with for the UK focus market.

The build
I am using the ford explorer rear IRS from 2002 to present, there spline count is 31 and 29 outer.
They are rather large but made of aluminum and can withstand huge hp numbers. I will retain the
stock explorer cv and outer flange and bearing, the cv is overkill but cheap and plentiful.

The diff will be mounted with similar geometry as the stock focus, the was the diff is made allows
for mounts that will make the diff pull out from the bottom making changing them in to 8 bolts,
4 for the drive line and 4 for the diff on a 06 plus and 3 for a 2002 to 05.

I will be making a fabricated rear knuckle and use the focus trailing mount its tucked up and in
which is great for protection. The knuckle with be shaped with a void at the bottom so
when you unbolt the hub you can pull the hub brake and cv at once. With this you can change a
cv in 3 or 4 minutes.

The back of the car has quite a bit of room but will require a small tower to be installed for
a coil over shock, My goal is 12" of travel with the set up. The rest will be bolt on.

in the front I will retain the stock power steering and build a new direct bolt on frame
and move the rack forward and bolt in from the bottom. with this there will be the
second peace of fabricating, of installing a small preformed tranny tunnel that
would be best welded in.

motor mount will have to be fabricated but should require little to no welding on the car, due to
the existing mounts on the passengers side and fabricated ones on the drivers side.

front suspension will not be changed unless wanted I do plan on making long travel
parts, with fabricated arms but this would be icing on the cake.

The bolt pattern will be changed to 5 on 4.5 and the mazda 3 knuckles already have this
in the front and swap over. for brakes I will make a large brake kit but again thats more
parts that are outside of the RWD swap.

Thanks for reading This is what I hope to make my niche for years to come.



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