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how to build a rally focus

30K views 21 replies 16 participants last post by  TomasC  
#1 ·
hi guys:
Recently, i started to think that if i want to build my own zx3, i want it's different. So i decided to build my own focus wrc. However, i have no idea how to build or what kind of parts do i need to build one.
For example, What kind of suspsions am i looking at, Rally special? or, How to increase only torques(since my zx3 has 171 whp 161 wtq)? I want my torque hit 230.
it is a lot of work to do, but it is gonna some much fun.

there are enough street racers. I want to be different.

[???:)] [???:)] [?|] [thumb]
 
#2 ·
loverpig said:
(since my zx3 has 171 whp 161 wtq)?
wow, you have a SC or something? those are big numbers for a zx3, even with all the bolt ons....
I'm doing the rally theme with my Euro SVT, my car club (its actually a truck club hehe) is building a rollcage and engine skid-plate here soon to start it off as well as some 15" rims with michelin rally rubber on them (good for winter tires too) for they days I go hit the backroads/logging roads around here.
As far as Torque, the easiest way is of course a turbo system build for torque insted of HP, thats what most of the WRC run
 
#4 ·
thats awesome... i'd say buy a RS or cosworth, it'd be easier ;)

with a zx3, i dont know the exact upgrades, but you would need a body kit, rollcage, weight distribution (50/50 for best control around corners) not sure of the exact suspension kit, but a rreally good one..

why dont you check out a rally site, i can guarantee they will have something about the Focus' parts.
 
#6 ·
Yea your numbers sound bogus to me. 171 whp and 161 wtq, thats a healthy NA build or a FI build and it seems like you don't know anything about modding, so I am asking, where did you get those #'s?

You can build a rally car to race in amateur rally races, or are you just talking about building a rally replica to drive around on the street?
 
#7 ·
I'm keeping mine street for now but I am going with the rally body kit and look. Rally cars are not just for dirt, they are for the street also. When my Focus is a couple years old and I'm in the market for a new car then I will strip out the inside and totally rally it out. Until then I need to get practical use out of it.

You can find allot of stuff at FordRacing. They have the Body Kit...
 
#8 ·
Michelin rally tires are terrible winter tires as are all rally specific tires, the sidewalls are way to stiff to allow traction on snow. Rally cars use special winter tires that are about half as wide as a rally tire with long studs when allowed. In a pinch (here is the US) Blizzaks and Nokians are used at snow rallies as studded tires are not permitted by our rules. Rally tires will not last on pavement as well they'll be bald in 500 miles or less!!!

Building a rally car is not simple (mine took me over two years). A rally car is incredibly stiff. This is done by stripping the interior, seam welding it and the installation of a full roll cage ($1000.00 to $3,000.00 ...sorry cheap bolt in kits not allowed) with anywhere from 8 to 20 or so attachment points. Attaching the cage to the body shell with gussets is what really stiffens the whole package. A rally suspension of decent quality will set you back 2 to 3 K just for the shocks (DMS etc.) All under body brake and fuel lines need to be moved to the interior of the car in new solid metal or stainless steel hose. I could go on and on but it will cost about 7500 K on the cheap side and upwards of 25K to convert a street car to a real rally car. That's does not include any work to the motor or trans. Yes you can build a "look alike wanna be" for a whole lot less but that's what it will always remain.
 
#10 ·
Geezer said:
Michelin rally tires are terrible winter tires as are all rally specific tires, the sidewalls are way to stiff to allow traction on snow. Rally cars use special winter tires that are about half as wide as a rally tire with long studs when allowed. In a pinch (here is the US) Blizzaks and Nokians are used at snow rallies as studded tires are not permitted by our rules. Rally tires will not last on pavement as well they'll be bald in 500 miles or less!!!

Building a rally car is not simple (mine took me over two years). A rally car is incredibly stiff. This is done by stripping the interior, seam welding it and the installation of a full roll cage ($1000.00 to $3,000.00 ...sorry cheap bolt in kits not allowed) with anywhere from 8 to 20 or so attachment points. Attaching the cage to the body shell with gussets is what really stiffens the whole package. A rally suspension of decent quality will set you back 2 to 3 K just for the shocks (DMS etc.) All under body brake and fuel lines need to be moved to the interior of the car in new solid metal or stainless steel hose. I could go on and on but it will cost about 7500 K on the cheap side and upwards of 25K to convert a street car to a real rally car. That's does not include any work to the motor or trans. Yes you can build a "look alike wanna be" for a whole lot less but that's what it will always remain.
Ok first off, it doesnt snow that much at all in the Seattle area, and I mainly want the tires for the weekends I go hit some dirt roads and in the winter to save my Euro rims from getting beat to crap by the sand/salt on the roads....
Second, this is my daily driver and is brand-new, so of course I'm not going all out 20k rally car, just some simple stuff to keep the car running good when I hit the trails on the weekend, the rollcage is one of those "just-in-case" items we're putting in to be on the safe side because some of these logging roads have very steep dropoffs on one side of the road, not that I'll be sliding around those ones but you never can tell what might happen. We do drive the roads first to see whats ahead.
Funny side-story, we did a drive-ahead run up a logging trail near the ocean, big road maybe close to 3 lanes wide, was sweet coulda ripped those corners great (ps this was in my 99 cougar) but about 2 miles in, with no warning signs whatsoever, there is a bridge around one of the large corners, nice HALF of a OLDASS WOODEN BRIDGE!!, so glad I wasn't goin but 15mph cause if I had been on it there is no way I could have stopped in time, and it was a nice drop to that very overgrown river hehe, was fun to walk around there though, was erie though as there was only half the bridge there, nothin on the other side of the bank besides the concrete foundation =(
anyway I took too much time writin this...off to mini-golf and Shrek 2 =))
 
#12 ·
man i hope you have an extra vehicle...
when you auto-X the car you can suffers alot....
i dont wanna see how much it will sufer becouse of a rally track...

it not as easy as it sunds...
you will need a good suspension and tires and VERY strong rims....

good luck man
 
#13 ·
Re: Re: how to build a rally focus

~04~SVT~ said:
as well as some 15" rims
Wow. Please let me know what 15" rims you find that will fit over our front brakes.[???:)]
I'd much rather have 15's than 16's for my winter wheels.
 
#14 ·
Going to go to discount tire soon and see what they can find out, as well as if they can get the tires themselves, if not I'll probly find and online company that sells wheel/tire package, there is a place that does full rally conversions a few hrs drive from here, can see what they offer but alot of their stuff is pricey since they do the whole rip your car apart with internal suspension, roll cage from hell, etc.... like cascade rallye or something along those lines
 
#15 ·
If u want to do cheap/quick suspension go to ur local salvage yard and find a SMALL ford truck take the coils, install. gives ur focus stock-ish ride height for ample ground clearence, but r a bit stiffer for handling. dont be afraid to change ur car just go for it. make mistakes and learn from them.
p.s. the rear seats weigh a ton lose them, move ur battery to the back. quick simple.