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Discussion Starter #1
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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Discussion Starter #2
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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Discussion Starter #3
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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Discussion Starter #4
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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Discussion Starter #6
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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Discussion Starter #7
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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Discussion Starter #8
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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I approve!
 

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Discussion Starter #11
And today it is off for an alignment. Cant wait to put some miles on the new setup! The tires make the car look much more complete as a rally setup, as shown by the before street tires pictures and after new larger tires.
 

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That's good to hear! Can't wait to test the setup! I'm sure this fall I'll put it to the real test at some point with some 2 tracks to get to hiking trails!
keep in mind your header is the low spot of the undercariage and prone to damage. Might consider a skid plate.
mine cost $50 for a scrap sheet of 3/16" aluminum and a 6 pack of beer for the guy at work to weld some mounts together.
 

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Discussion Starter #14
Yep, thats the next agenda item to design and install in the spring. My pre-cat O2 sensor is snapped off due to that low spot and some deep gravel holes in a parking lot from before. I plan to design something I can incorporate driving lights into to like a rally innovations bumper.

keep in mind your header is the low spot of the undercariage and prone to damage. Might consider a skid plate.
mine cost $50 for a scrap sheet of 3/16" aluminum and a 6 pack of beer for the guy at work to weld some mounts together.
 

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Discussion Starter #16
Thought I'd give an update, have not had a problem with the focus since doing the rebuild. It handles everything I've thrown at it so far well, even with the open diff. I've done some pretty deep snow running on all-seasons her in Michigan during our lovely snow storms of this winter, and no problems at all. Plenty of ground clearance and very stable and predictable even on the snow and ice.
 

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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.
been looking for those taillights from Spec-d and cant seen to find them. where you buy them at? and what model are they?

you got a sweet ride.
 

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Discussion Starter #20
been looking for those taillights from Spec-d and cant seen to find them. where you buy them at? and what model are they?

you got a sweet ride.
Thanks, the taillights I actually got from Amazon. They do not fit right on the car thought, as the plug cutouts were the wrong shape so I have to modify both the bulb housing and the tail light to keep them from falling apart.
 
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