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Old 09-20-2018, 03:26 PM   #1
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Rally Focus SVT Build

Thought I'd put my build into a thread, as it is almost coming to an end for now. I bought a Focus SVT as a winter car back in early 2017, I knew it needed the brakes rebuilt, and planned on eventually making the ultimate "adventure" focus for my obscure hiking trips and backroad/light 2-track running at times around Michigan. Maybe down the road do some rallyx or other races. Definitely had a lot of help from theNorm about his setup, and did a little self work on my own. I will go through the process below in more detail.


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Old 09-20-2018, 04:48 PM   #2
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Bought the focus from southern Illinois with around 85,000 miles on it, and always had the plan to give it a lifted "rally" look, and possibly use it down the road for some light rallyx. Always have like the look of rally spec cars. My little brother bought a comp orange about 4 month after I bought mine since he liked the look of mine.
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Old 09-21-2018, 09:53 AM   #3
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I am using theNorms suspension setup for his rallyx focus. I got a brand new focus svt strut kit (front/rear), zx3 springs for the front, and progressive wagon springs for the rear. I used his rough size of the aluminum spring preload spaces for the front strut assembly (as shown in the picture) to rough turn the spaces, and finish machined them to tight slip my individual top strut bearings and upper spring retainer. All was completed out of 4.5" solid 6061 aluminum bar.
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Old 09-22-2018, 10:56 AM   #4
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I had a lot of general maintenance items to do also, all of the bushings were worn out in the suspension, especially on the control arms. After getting into it, I figured out the front wheel bearings were also in terrible shape, so I put new hubs all around the car. In taking the rear control arms and springs off, I actually found that the passenger side spring was broken. To get a level ride height, I also cut one and a half coils out of the higher spring rate side of the progressive wagon springs. (Most of it was dead coil anyways.) Getting the control arm and trailing arm to bolt back together was tough with the wagon spring due to the spring rate, the rear end of the focus was actually picking up off the lift with a jack under the control arm instead of the spring compressing. It took adding weight to the rear trunk to get them put together.
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Old 09-22-2018, 10:59 AM   #5
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More pictures of disassembly and assembly.
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Old 10-01-2018, 09:52 AM   #6
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The brakes were all replaced, with Centric cryo treated rotors and Hawk HPS street pads. Also included a picture of the replaced part carnage. I actually aligned the car as best as I could, and did some test running of it on the worn out tires to make sure there where no major issues to work out before the final alignment with the new wheel and tires. With stock 215/45r17's I gained 2" ride height over stock, as measure between my younger brother's SVT.
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Old 10-01-2018, 10:00 AM   #7
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I opted for 16" Sparco Terra wheels with 215/55r16 Continental ExtremeContact DWS06 tires. I picked the tires size based on theNorm being able to fit 205/65r15's without rubbing, which are 25.5" OD. The 215/55r16 are 25.3" OD which just clearance the SVT size skirts in the back. There should be no rubbing even under full turn. I really wanted to pull the rear wheels out as the car looked odd with the rear track with pushed into the fenders compared to the front, even with the 42mm offset wheels. I opted to by OEM Ford 10mm spacers from PumaSpeed that go between the trailing arm and the spindle, therefore not putting any extra stress on the rear wheel bearings.
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Old 10-01-2018, 12:16 PM   #8
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I also did some changing of my taillights, because one of my Eurostar ballasts died. (I picked them up used a year ago.) I ended up going with Spec-d, as they seem like the most quality LED taillight on the market currently for the older hatchbacks without a clear lens (I hate clear taillights on a dark car). I did stick with the Euro tail light setup, and finally installed new reverse lights. I used offroad LED lights mounted under the rear bumper so they point through the rear Euro bumper grill. I also went with yellow LED blinker bulbs to make everything LED. The Spec-d lights do fit much better than Eurostars actually, which surprised me. I just had to modify the plug holes, as they were wrong, and then just siliconed to bulb sockets in. I soldered weatherproof plugs farther down the lead so the bulb sockets don't need to be removed to removed the tail light.
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Old 10-01-2018, 06:50 PM   #9
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I approve!
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May 2014 ROTM, June 2015 ROTM
for rally-x: '04 Liquid Grey ZX3
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Old 10-02-2018, 01:06 PM   #10
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The final build element was to add RallyArmor mud flaps, as the stance is wider. (The sidewall of the front tires is actually a little outside the front fenders.)
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