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Old 09-01-2013, 12:50 PM   #1
MaxAtk
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2004 Focus Rally Build

At the beginning of April I embarked on my 2004 Ford Focus Rally Build. New to Ford in general and have really enjoyed building the car to date. Just a few more months to go..... intend to write about the good, bad and the ugly when it comes to building your own rally car.

Here it is after driving it back from the auction. Cost to date: $1200






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Old 09-01-2013, 01:54 PM   #2
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Max. Looks like a good investment so far. Is it a 2.0 or a 2.3? What do you have planned? Keep us up to date, especially with pics.
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Old 09-01-2013, 02:15 PM   #3
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Finally a REAL rally build... haven't seen one of those for awhile. haha.
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Old 09-01-2013, 11:45 PM   #4
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find us over in the rally revolution group. we have another member who just bought a svt shell as a project and does some work at the Ojibwe rally in Minnesota. lots of good stuff in there. sub'd to see where this goes
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Old 09-03-2013, 01:53 PM   #5
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Let the gut out begin. Didn't cost much except some man-hours. About 10 hours if I remember right, this included removing all the sound deadening material. Thankfully there was not very much of it. A few hours with a heat gun and scraper. Dry ice place was closed...









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Old 09-04-2013, 02:14 PM   #6
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The engine is the 2.0 Zetec. Current plans for the engine are 11:1 CR JE Pistons, K1 Technologies Rods, Stock Crank, MAHLE Clevite Bearings. Will most likely be going with a Massive Ported Head shaved 0.04 with 0.04 head gaskets, ARP main and head bolts. CR should come in around 12.5 CR. Will primarily be run on Motorsport 109 fuel with a 93 map created purely for a commute to a show, etc. There are many other bits involved but this is a quick summary...









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Old 09-04-2013, 02:16 PM   #7
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Oh, man hours to date: about 20 to get to this point....

No more cash outlay...... YET!!!!!!!!!!!
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Old 09-05-2013, 11:47 AM   #8
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What will you be running for suspension?
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Old 09-05-2013, 07:48 PM   #9
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Suspension I am running JVAB 50mm Coilover Struts in the fronts, a little over 8" of travel. The rear I converted over to coilovers as well with spherical control arms all around and Massive camber arms. After putting the whole thing together I decided the whole set up would be awesome for the track but there were too many points of failure for Rally. Also the travel in the rear was almost 10" and the stock geometry experiences way too much toe in and toe out movement at the far end of bump and droop. Switching over to McPherson set up in the rear as well with a custom sub frame and lower control arms, etc. I'll post more pictures up tomorrow when I can size them for forum viewing.
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Old 09-05-2013, 11:01 PM   #10
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Quote:
Originally Posted by MaxAtk View Post
Suspension I am running JVAB 50mm Coilover Struts in the fronts, a little over 8" of travel. The rear I converted over to coilovers as well with spherical control arms all around and Massive camber arms. After putting the whole thing together I decided the whole set up would be awesome for the track but there were too many points of failure for Rally. Also the travel in the rear was almost 10" and the stock geometry experiences way too much toe in and toe out movement at the far end of bump and droop. Switching over to McPherson set up in the rear as well with a custom sub frame and lower control arms, etc. I'll post more pictures up tomorrow when I can size them for forum viewing.
Very interesting...

Saw you over at rallyanarchy....

Hope you post up either here or there with details on the Mcpherson rear.
I can see where there could be toe issues with the stock geometry with longer travel.

But most Foci rally drivers are doing ok with either the stock flimsy arms and spares or spherical as you've done already.

Are you working with John at JVAB on the Mcpherson rear?
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