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-   -   Thenorm's Rally-x build. (https://www.focusfanatics.com/forum/road-racing-rally/667378-thenorms-rally-x-build.html)

thenorm 05-11-2016 11:48 AM

Thenorm's Rally-x build.
 
I've dabbled in rallyx before, but now I'm going to convert my Focus to a rally-x car, since I bought a Mustang GT for my autox fix.

This was the starting point.
http://i2.photobucket.com/albums/y24...psqbhy8d6y.jpg

step 1, remove and sell Mustang wheels for something a little narrower. (fender flares are coming off too)
http://i2.photobucket.com/albums/y24...psilztblco.jpg
http://i2.photobucket.com/albums/y24...pssm8pkatc.jpg

step 2, buy cheap SVT shocks struts.

step 3 spacers for the front struts.

This was the protoype. these worked quite well.
http://i2.photobucket.com/albums/y24...pslhzbberi.jpg

next was aluminum. final version was 29mm thick.
http://i2.photobucket.com/albums/y24...psme77iomz.jpg
http://i2.photobucket.com/albums/y24...pspnmdcaog.jpg

I had to indent the back side to get enough travel on the shocks before bottoming out, and still not coil bind.
http://i2.photobucket.com/albums/y24...ps3vjopvhh.jpg
http://i2.photobucket.com/albums/y24...psj0tfisej.jpg
http://i2.photobucket.com/albums/y24...psbvpzsq9t.jpg

http://i2.photobucket.com/albums/y24...psdkwzsbsq.jpg


step 4. install spacer/strut front and Wagon springs rear. I now have 7" ground clearance under the SVT header (a notorious low spot)
http://i2.photobucket.com/albums/y24...pshuwo9uyu.jpg
http://i2.photobucket.com/albums/y24...psphm6t5sy.jpg
http://i2.photobucket.com/albums/y24...pswvwemm1l.jpg
http://i2.photobucket.com/albums/y24...psxq637ynp.jpg

thenorm 05-11-2016 11:55 AM

These are the tires i plan to install as well as my skid plate.

I will also install mudflaps.

Team dynamics pro race 1 15x7" clears SVT brakes. gravel rally tires.
http://i2.photobucket.com/albums/y24...psmppdojis.jpg
http://i2.photobucket.com/albums/y24...pstpck5oyd.jpg
http://i2.photobucket.com/albums/y24...psw6cnhchu.jpg

the skid plate is custom made 3/8" aluminum. for an oil change, its just 5 bolts. to remove.
http://i2.photobucket.com/albums/y24...ps2dboubjb.jpg

the uprights that bolt to the front subframe, using exisitng bolts on the tie down point and radiator mount.
http://i2.photobucket.com/albums/y24...psigunlwsl.jpg
http://i2.photobucket.com/albums/y24...psolzbhq7g.jpg
the captive nuts that I insert into the subframe, so i didnt have to drill holes.
http://i2.photobucket.com/albums/y24...psbbiiyt0c.jpg

i've been through 3 progressively larger pieces of angle iron for the cross piece. as I keep bending them. the current largest one i had to notch to clear the SVT header.

http://i2.photobucket.com/albums/y24...psawsaxf6z.jpg

thenorm 05-11-2016 12:46 PM

just random thoughts here...

this is the ST suspension 0.8 inch "spring distance kit" that I based my spacer off of.
http://i1112.photobucket.com/albums/...porary-109.jpg

coincidently ,the indent in the back of my spacer was 0.8 inch, so on both the ST and my spacers, the bump stop is in the same relative position. and would have the same travel (SVT struts on stock zx3 springs)

in total I have 6" total travel from full droop until the springs coil bind, but the bump stops should bottom out (compressing 2" down to 0.5") in 5.75"

bringler26 05-11-2016 01:11 PM

10 Attachment(s)
Awesome build! I was sad when I first saw you were selling parts but this is a great reason to be doing so!

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dnjnkns 05-12-2016 09:58 PM

Great write up!!! Looking at trying something similar with my mk3 suspension wise http://uploads.tapatalk-cdn.com/2016...be6964e118.jpg


2012 Ford Focus SEL "MK3"
2009 Ford Edge Limited
2007 Harley Davidson Sportster 1200L

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sailor 05-12-2016 10:29 PM

Another well thought out build.

Love the spacers, and wagon springs for the rear is simple genius.

thenorm 05-13-2016 10:06 AM

Quote:

Originally Posted by sailor (Post 9792273)
Another well thought out build.

Love the spacers, and wagon springs for the rear is simple genius.

thanks,
but hold that thought on the wagon springs. although they are tall, they are also stiffer than the fronts, so sometimes i get a bit of a donkey kick going over some bumps. I'll probably stick with it for now (i dont have regular stock rear springs) but i may consider regular springs with a spacer. however the spacer is a little more complicated than the simple cylinder i turned for the front, so I need to think on how to make it. I don't pretend to be a machinist, im just a hack.

slow_solo_focus 05-15-2016 12:07 AM

Interesting deal you got going on, sub

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sailor 05-15-2016 12:35 AM

Sounds like more damping time at the rear then, and maybe more stiffness at the front.

Subie never solved the hatchback's issues in flying compared to the sedan, so weight & balance comes into that part. Donkey kick should be able to be tuned out easier though, separate problem.

thenorm 05-15-2016 05:03 PM

More damping for sure, balancing the stiffness in the front would help, but I'm trying to be cheap with the Svt dampers.
I've heard that ranger springs might fit so it's a idea I need to investigate


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