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Discussion Starter #1
I'm starting to look for a shell. I want to do an AWD swap. From some quick research I would like to use a 4G63 and use the 8.8 limited slip from an Explorer. I'm not sure yet how the engine would have to mount as I'm just in the research stages. Figured I would post this up as an idea since I don't have enough posts on here to put up a wanted ad in the classifieds. This won't be a short term project, but I am planning on working through this over a few years. I will be sure to post back here with info as I go. If anyone knows of a ZX5 shell, let me know. I don't want a sedan and I need a 4 door for the kids.
 

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Discussion Starter #2
FYI, I will be building sheds on the side to fund this project. If anyone needs a shed built and they are close to northern Indiana, let me know. I can PM you detail.
 

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Fins Up!
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no one on this site has done one. there are some awd swaps over sees but you will see nothing of them but a couple vids.

if you do a 8.8 go with the mustang rear not the explorer.. 4 link instead of leaf spring.
 

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Meh.
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Haven't seen any on this forum but I sure know that I would love it if my car were AWD. Good luck and feel free to start a build thread when you start. I would love to follow your progress. [thumb]
 

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Discussion Starter #5
Well that is the plan as soon as I find a shell or a car I can part out. Going to start putting some parts lists together tonight.
 

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Discussion Starter #6
Here is the plan and decisions that need to be made as of now.

1. Find ZX5 shell
2. Strip any drivetrain out of it and sell that off
3. Rewire to make all interior stuff still work
4. Determine which way to mount engine (this will determine if I use a full 4G63 front drivetrain or if I will have to use a 4G64 mounted to an Evo 8 front drivetrain)
5. Mount/wire front drivetrain
6. Mount rear axle
7. Build driveshaft and exhaust.
8. Fuel and air.

These are my initial thoughts and order I want to tackle things. Obviously this is just a start and will likely change as I find specific parts.
 

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Sneeze
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Heard lots of talk about people doing this... not 1 person has followed through.

Here's to hoping your the first. Good luck to ya!
 

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Discussion Starter #8
Got some interest in a couple of sheds today so if I can get those sold, then I should have enough cash to start looking for a shell. Once the cash starts comming in, I'm going to start on it.
 

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to bad you want a zx5. there is a roush at the salvage yard. it is a bit banged on right side. but it is fixable. my frnd owns the yard, if i had a garage to put it in i would buy it. he is asking 2grnd. me & another member looked it over. looks to take about 1200/1500 to repair. black on black rally edition also.
 

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Discussion Starter #11 (Edited)
I like the ZX3 better, but I need something I can put the kids in the back of easier. If I can't find a ZX5 or if I come across a ZX3 for under a grand then I'll probably pick it up. My goal is to sell off the parts I don't need and have around $500 tops into the shell. If I can get that I will be happy with the start.

By the way, I like the sig. You a Ramsey fan?
 

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By the way, I like the sig. You a Ramsey fan?
i had that saying on my rear window of my drag car back in 1992. it jst came to me one night. also had one that said " speed kills, drive a chevy live forever " but dave is a good man & tells it right.
 

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Hope you get it done. itll be sweet. i wanna do one i have the experience to do something like that but i dont have time nor money right now and "too many other projects" says the wife haha
 

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Discussion Starter #14
I'm on the path...just need to find a shell...and convince the wife it's a good idea...
 

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@ kicker:

Hey, I've got a cnc plasma cutter down here in Farmland, so any mounting brackets that are needed will not be a problem. I've got welders, torches, powder coat, yadda yadda. (just opened a fab shop) I'm also driving a ZX5 thats' trans feels like it will drop out any f%&king day now.

Any interest in a joint project, or just want it to be all yours? What are you looking at spending on a shell, if you want to do it alone?
 

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Discussion Starter #16
The Boss:

I like the thinking but I'm not 100% of the timeline on this. I am going to cashflow the project so if the cash slows down, then the project will be slowing down. I'm planning on it being a longer term project. I like the idea of having a hand, but I don't want to tie anyone else down on my timeframe. Although, knowing you have the tools, when I am able to do it I will definately get ahold of you. As for as a shell, my goal would be to find one for around $500-$1000 depending on the shape of the body and interior. Obviously I don't care about the drivetrain/PCM/trans parts/ECT. I would pay more if there were enough valuable parts to sell and get the cost down. Until I get to dig into the wiring, I'm not sure what all I'll be able to sell. I suspect the Airbag modules won't work, but I need to dig in and see if the Airbag module gets the speed signal from the ABS or PCM. Just one of the small wiring tasks I've been thinking about. Would be nice to keep the ABS too, but not sure if that will be possible yet. Just need to see what I will get into. I'm hoping to be able to buy the shell in the spring and get it stripped and functioning next summer while I source out the drivetrain.
 

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Kicker-I thought about this as well. When it came down to total expense it just made sense to buy a whole evo and just drive that or a subaru sti. I wish the best to your build, but like everyone says people have been talking about it for along time on here but realized the cost and just moved on to something different.
 

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Discussion Starter #18
I'm not quite sure I agree with the costs thing. If you are going to use an Evo drivetrain, then yes, it will cost about the same by the time you find all the good parts. This is my overall breakdown so far for my plan

Shell - $500-$1000
Drivetrain - $400-$500
Wiring and ECU - $200-$300
DSMLink - $400
Kugel Komponents 8.8 Bolt in kit $1200
8.8 Diff $100
Driveshaft $400-$500
Engine Mount Brackets - $200
Misc hoses and general stuff - $400

I'm sure there is stuff that I'm missing, but that puts the cost at $3800-$4600
Bump some Evo injectors and an Evo III turbo and you should be able to put 300HP/TQ at the wheel. So you now have a $5000 11 second Focus. I compared the weight and the focus is only about 200 lbs over the 1G DSM and I know that setup will hit mid 11 seconds

Take that 1 step further and build the 2.0 to a 2.3
Stroker pistons and rods $750-$1000 new $500 used
2.4 Crank $150
20G TD05 Turbo $300-$500
Injectors $200
Walbro 255 $50
Clutch and Trans Improvements $600
Solid Tune - $300

Upgrade cost
$2100 - $2800

Estimated total cost
$6600 - $7400

$7400 and now you have roughly a 10 second Focus. I love Evos and STIs, but there is no way I'll find a stock one for $5000 nor a 10 second one for $7400. Now again, this is initial costs. I'm sure I would get into more, but I would have to spend twice as much to get an Evo and 3 times as much for an STI. Plus there is that one off feeling and saying "Yeah, I did that." Not to mention blowing the doors off some unsuspecting muscle cars.

My biggest struggle right now is I'm not sure what the front suspension will need for mounting. I won't know that until I get my hands on an actual shell. I want to use the factory DSM knuckles so I don't have to source out weird wheel bearings. I am thinking I might have to do some searching to get ball joints that will match the Focus control arm and the DSM knuckle. Might need to have a shop bore out the knuckle just a little so the joint will fit, but again, I need to get my hands on a car first.
 

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Meh.
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Those numbers are all fine and good, but when you actually start digging in, you'll probably find many hidden and unplanned for costs. I'm not trying to discourage you or anything but with any major project like that, there are bound to be problems and added expenses. Furthermore, this is just the dollar value, it will take a lot of labor to get something like this done so you can't really compare this project car with going out and buying a Evo or Sti.

But as you said, owning a one of a kind car is priceless.
 

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Discussion Starter #20
I see your point and I know there will be more involved in it than just this. Fortunately I was a Ford tech for 8 years so I know my way around a wrench. I'm not planning on paying anyone to do anything other than cutting some parts for me. I'm doing everything else so my labor is free. I'm sure at a standard shop rate of $85 an hour you would end up with $3000 in labor. For me there is a huge pleasure in doing the work. I sit at a desk all day now and I really need something to keep my busy at night after the kids go to bed. Plus I figure if I'm going to sit around for 4 years and save money to go buy a WRX, then I might as well build a faster Focus (which I've always had a soft spot for) for the same cash and kill two birds with one stone.

I like the discussion. Keeps me thinking about this project. I won't be able to buy a shell for a few months so I need to keep my brain going on it. I really am taking the time to try and think of all the angles and problems that might come up. I don't want too much to sneak up on me. I might get into it and find out the the engine won't even fit in the car, so who knows. Until I get a shell, it is really all just theories.
 
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