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Shlammed Life
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that's one hell of a design for the rears. I wonder how that would react in a street setup... hermmmmm. subd for moar rally porn
 

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Discussion Starter #22
A little more of an update on the rear suspension. In Gravel Rally mode, the suspension travel is a little over 9". This was maxing out the 3/4" high misalignment spherical bearing at max droop. So, I made a new set of lower control arms with a bend in it to take the load off the bearing. Also another note, the current sub-frame was made up to verify all the geometry. I'm going to make a more streamlined tubular one using bends, instead of cut angles and welds. This sub frame uses the stock sub frame mounting points. The new one on the drawing board will use some new mounting points.

 

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Discussion Starter #24
Here is some steering column work. Pretty straight forward racing column with a 2:1 quickener thrown in the mix for now.

 

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Discussion Starter #25
that's one hell of a design for the rears. I wonder how that would react in a street setup... hermmmmm. subd for moar rally porn
Since all WRC cars run a McPherson set up in the rear whether it's tarmac or gravel I'm sure it would be fun on the street as well. Now whether it's worth converting a street car I don't know. The biggest knock on a McPherson set up is camber changes on extreme bump/droop. The longer your arms the less of a problem this is, and with shorter travel of tarmac suspension probably not a huge deal in performance. For tarmac set up, you can run a shorter damper and spring.
 

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Shlammed Life
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So, how much love would you need from me to get my hands on one of these setups
 

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Discussion Starter #27
So, how much love would you need from me to get my hands on one of these setups
Once I finalize everything the components are pretty straightforward to make and I plan on publishing the dimensions. The biggest thing is welding in the strut towers but if you're comfortable cutting out your wheel wells, notching the frame a little and welding it in then I'm sure I can make a set of everything. I'll probably make another set of everything for myself as spares so maybe making a few sets could be more economical.

PM your info and I can keep you posted.
 

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Discussion Starter #28
Also, depending on the final sub frame you may have to rework the end of your exhaust system... TBD though...
 

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Haven't rallied a Focus in a while. It looks like you've already eliminated most of the issues we had when running ours. Very nice build. Love the simplicity and stoutness.
 

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Haven't rallied a Focus in a while. It looks like you've already eliminated most of the issues we had when running ours. Very nice build. Love the simplicity and stoutness.
Curious,

what issues?
 

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Suspension binding, flexing, destruction of subframes. Short story- we were pushing an old car pretty hard and after the first few rolls it started to have issues tracking straight.
 

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Suspension binding, flexing, destruction of subframes. Short story- we were pushing an old car pretty hard and after the first few rolls it started to have issues tracking straight.

So rear suspension issues?

Sorry about all the questions but...binding and flexing of the rear links?

Were you running stock links/arms /control blades in back or any reinforcing or tubular arms?

Did you "double skin" the rear subframe or just stock?

Stock inboard spring or coilover?

Thanks!

Mike
 

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Discussion Starter #36
Now that I have the rear figured out, I'm making a lightweight but equally strong rear subframe. Getting rid of all the welds and 90 degree joints. Going with a tubular design deviating from the stock mounting points. Anyhow, here are some pics of the front. Stock front subframe, sandblasted and powdercoated. CFM Front LCA's. 2005 ZX3 Knuckles. JVAB coilover. Need to turn my attention to those front tie rods. Those things are a failure waiting to happen...




 

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Bro you are freaking awesome... I'm going to school for automotive technology and I hope to get to this level with years of future experience

Sent from my LG-P769 using Tapatalk
 

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Discussion Starter #38
Thanks for the encouragement. I actually had absolutely zero experience working on cars when I started this. Always wanted to build a rally car and here I am. I think if I knew better that I would not be building it, lol... but jokes aside, it has been really fun so far and it is going to be even more fun running it...
 

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2006 tie rod inners and outers are a direct bolt in and they dont bend due to a straight outer design vs. the bent design of the pre '06. You will need both inners and outers to do the swap though as its a different thread pitch on the inners where the outers thread on. We've been running them for years on both team cars as we were bending the ones you have often.
 
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