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Discussion Starter #1
Hey all

I figured I would start a thread about our 2003 ZX3 rally build. We just finished Oregon Trail Rally last weekend, and thought I would share some of the interesting things we have done on the build. OTR was actually our 2nd stage rally, we did Big White Winter Rally in Canada last December and finished that one as well.

The car is a Cali model 2.3 dtec with zero options, not even a/c. I flew down to San Fransico in late 2015 to buy it. Originally the plan was to replace our MINI cooper in solo in STF, as we were getting out powered on the big national style courses. I bought some of the standard bolt on parts to run in STF and ended up running two local events in the Focus, honestly it was/is a terrible autocross car, the ergonomics, the hanging throttle, and lack of weight transfer determined it's fate.

So I pulled the plug on the STF build and put the car back to stock in preparation to sell it locally. I sat on it for awhile, in the meantime my wife and I entered the Boise rally in a rented Geo Metro, and we had a blast. After that she convinced me to keep the focus and build it into a stage rally car. In the summer of 2016 we stripped the interior, build a 1/4 aluminum skid plate, transfer in our OMP race seats from the MINI, and sent it off to get a rally cage.
 

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Discussion Starter #3
Sure tell me how, I have had trouble in the past uploading pics.
 

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8 DAY HOMECOMING
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Mobile version: tapatalk
Desktop would need to be like Photobucket or imgur

I like tapatalk for direct upload.

Sent from my SM-G925V using Tapatalk
 

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Discussion Starter #5
We just finished two more stage rallys idaho and Colorado. Going to upload some pics of the beast. Stay tuned
 

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We just finished two more stage rallys idaho and Colorado. Going to upload some pics of the beast. Stay tuned
We await...

And don't use photobucket!
 

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Discussion Starter #7
We have been busy prepping for the last stage rally of the year. Installing a Howe steering quickener, a bigger fan for the heater box. I also bought a fswerks 2.5 header back exhaust
 

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Discussion Starter #8
Pic of 2.0 dtec which is coming out after this next rally. We picked up a 2.5 out of a fusion for short money, excited to feel the difference between the two
 

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Discussion Starter #9
Here's the wife test fitting the seat and wheel before the last rally.
 

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That green filter is costing you 2-4HP , air does not like to flow through foam , make a pipe like I make for the MK3 Focu intake , make the MAF built in and make it 3 inch , will work much better for you
There is some Vac lines and a few things I see that can be removed from under the hood for ease of working on it

Tom
 

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Discussion Starter #11
The rally season is over. Reprep for next year includes installing a mildly built 2.5 dtec, wilwood front calipers, remoting the air filter into the cab, cuting out the rear shock towers and welding in bigger boxes to accommodate the coil overs, installing rear control arms that are double heim jointed.
 

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Discussion Starter #12
Pulled the 2.0 out, in the process of prepping a 2.3 for a spare motor. Also trading out the cams and spring to put in the 2.5.
 

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Discussion Starter #14
What Wilwood setup are you going to run?
Currently catalog searching, but most likely a Wildwood dynalite pro, they share the same spacing and rotors at the 05 and newer focus knuckles
 

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Discussion Starter #15
Ordered up a Wilwood 4 piston fixed caliper to test fit, only $129 cheaper than rebuilt caliper and core at the local auto store.
 

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Discussion Starter #17
Caliper is here! Will get test fitting on that might be time to buy some tooling for my mill
 

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Discussion Starter #18
Some more work done. Cam washers from massive showed up, I got all my lifters dialed quite a few were out of spec. Front timing cover and new crank seal installed. Added a new ac delete idler pulley and t stat. I need to clean up the cam cover and install that and the motor is done
 

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Discussion Starter #19
Still plugging along. Made the front bumper support removable. Next up is reworking the power steering hose in a/n hose, got the kit from Alex. Also just bought a Aem standalone from a forum member
 

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This is sounding awesome. I built a 2003 2.3 PZEV stage rally car and I'm wanting to follow some of the same upgrade paths you are. I currently already have the suspension sorted with custom bilstein coilovers (the rear towers were cut out like you were talking about). I'm interested in what youre doing with the wilwood calipers. Which ones did you specifically get? Are you changing out the brake master cylinder with this?
 
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