Rally Spec Focus Build (56k beware)

[BigSandwich]

Hello All,

Well I am starting this thread to document the build of my ZX3 into a Spec Focus Rally car. I decided to go for this project about a month ago. The plan is to have the car ready to race in time for the first race of the NASA season which is Sandblast Rally on Feb 17th. So time is tight but I am confident that it can be done.

The car was purchased in Oct 2001, one of the last 2001's on the lot in North Carolina. It was my daily driver up until I started taking it apart. I was so excited to get started I didn't start snapping pictures until after I had some of the interior out

Nice interior going away


Who needs steering anyway.


Look Mom no dash


The spare tire well


The jack is holding the gas tank in the car.


The Gas tank is out. I didn't want the cage builder getting blown up.


The engine


Part Way through


The Engine is out


No radiator


Acouple more engine bay shots




Getting close


Now totally clean


Heater is out


No more tar paper




Getting ready to go to the cage builder


On the Rollback.


The car is now getting a cage installed. I am also having all four strut towers stitch welded. And getting some nice top plates put on the front struts to keep them from deforming when I hit big rock. I modeled my cage design after this one from Custom Cages in England.


Now I just have to start buying all the parts so I can put the thing back together in a month when the cage is done. Anyone who wants to help assemble the car let me know. I will keep this thread updated as parts start arriving and I plan on stopping by the cage builder to take some progress shots of the car.

Cheers,
Andrew

[chewbacca]

dude, awesome. definitely keep us informed of the progress. I wish i had the time and money to invest in a rally car.

[CWCZX3]

What are you doing with the old interior, i could so use it in my river rat was looking for one that i could purchase complete.

[mievil]

I wanna help. Wanna spring for a plane ticket? Awesome plans, man. And good luck.

[sleeperlove]

Dude have a G2G I would love to help some.

[rockthezx3]

Daaaaaaamn. I'm definetly subscribing to this thread. Good luck with everything.

[Primaris]

Does that cage meet NASA's requirements? It looks to have a lot of "points"

[BigSandwich]

Yes this cage meets NASA Rallysport specs. unfortunately it will not be leagal for the road racing series.

The cage should will have 8 points. But it will also be gussetted to the A and B pillars. And the bar that runs along the inside of the rocker panel will be stiched to the chasis. Ultimately the cage should be at least 50% stiffer than road racing cage. Plus when I roll it the repairs will be less.

[P-51]

How did you get the sound deadening tar out? Dry ice?

[BigSandwich]

I used a 2 part process. I used dry ice to get most of it off. Then I used a propane torch to soften the remaining pieces and peel them off. The hardest parts where where sound deadening was placed over seam sealer. If I had more time I would have looked into using liquid nitrogen rather than dry ice.

[ZX3autoxtasy]

Beautiful.

[DrewIsAmus]

Sweet! I might do something like this in about 5 years, gotta get a new job in October though.

[JimmySolo2]

Originally Posted by CWCZX3

What are you doing with the old interior, i could so use it in my river rat was looking for one that i could purchase complete.

My interior is mostly intact as well. Plus you want my A/C. lol

[John B]

Looking good!

Stupid question: Why did you have to remove the engine to install a roll cage? It LOOKS like the cage goes into the engine bay, but WTF?

[localhost127]

good stuff

are you looking to run any RA events?

[BigSandwich]

I took the engine out for 3 reasons. One, the cage will go into the engine bay and attach to the strut towers just below the main fuse box on the drivers side and the evap emissions contoler on the passenger side. Two, I am also adding a thick plate to the top of the strut towers so they will not mushroom up when the car jumps or hits a something bit. Three, I am having all of the spot welded seems around the front strut towers stitch welded for increased durability.

Localhost: I am not sure on RA events. Since NASA has contingency for spec foci I am going to concentrate on those events, but I am not going to rule out RA events. I had some cool parts come in in the last couple of days, plus I am going to swing by the cage builder tomorrow so I should have some more progress pics tomorrow.

[Silonius]

Awesome Andrew! I can't wait to see it sideways with sand flying up at Sandblast.

Wish I was closer too so I could come over and help out. Gorgeous cage! But why isn't it legal for road racing? Or just not legal for Spec Focus?

How much engine work are you planning on doing? Or are you just focusing (hehe) on getting it RSF compliant and getting some of that contingency money, with power mods to follow?

And what's gonna happen to the Scirocco? No I don't want it; I don't have a place to keep it or a truck to tow it.

[slidemaster]

Great thread!!

[BigSandwich]

The Scirocco was sold to a couple of brothers in Northern VA that want to get into the sport. That car should be at sandblast.

The reason the cage will not work for road racing is that with all the attachment points, the stitch welding, and firewall penetration I think I would be in some crazy class like e-mod or something where I would have to race against ground up race cars.

My plan is to have 3 versions. version 1.0 which will be ready for Sandblast is going to be just what is needed to be legal for the SRF and a couple of things that are easier to do with the car all taken apart like the stitch welding. The later versions will have the power mods, and hopefully some of the contingency money will offset those expenses. I hope to have the car to the sharp end of the spec by the end of the season.

Now onto so more updates. I started recieving parts in the mail. It is tough not having the car here. But cool things coming in the mail helps.

The nice ARP wheel studs. If you look close you will notice there are 5 per pack. ARP doesn't make Focus wheel studs but they do make them for a late model chevy camaro. So I will have 4 extras when I am done.


Aluminium seat brackets and bolts for my cool Racetech seats.


A couple of shots of the driver seat. This is the 4009WHR. Which means it has the head restraint wings and is made for people with a large BMI like me.




I got this cool mounting base for my seat. I think it will work well plus it uses the factory seat mounting holes.


Here is my wife's expression when it started to sink in how much money I was spending on the rally car.


BSCI FIA cert. Roll bar padding. Don't want the roll cage to deform my skull in a wreck. The FIA must know what they are doing because you could play baseball with this stuff and I don't think it would change shape.


Sparco Hood pins.


And now to the good stuff. I got this big box from LCRacing a sponsor here on the jet. Great price + fast shipping + Good service = happy customer.


Look some of the parts are even color coded for the season.


For those that wanted to know what a complete focus wiring harness looks like here you go. Only things that are missing are whats in the door and the hatch.


And to keep my self from going stir crazy with the car at the cage builder. I installed some extra lighting in the garage. If you are in the market for florecent lights get the T-8 kind smaller bulbs that use less electricity, last longer, and are brighter. Kinda seems like a no brainer to me.


And just so you don't think my wife hates the rally car. Check out what she got me for my B-day.

A 33 Gallon air compressor that came with 3 air tools. I was very excited. Will make putting the car back together that much faster.

Sorry I don't have any cage pics yet. My builder had a death in the family and had to rush out of town. Provided everyone stays healthy I will be going to test fit the seat and check on the progress this Saturday.

[sleeperlove]

what is the rally brake kit???

[BigSandwich]

The rally brake kit is basically the brakes off the '06 ST. The fronts are similar to the SVT but a little smaller so they will fit under a 15" wheel and they have rear disks.

The 15" wheel is required as 16" rally tires are really really expensive. Even the WRC guys run on 15" rims. And all of the subaru's and Mitsu's downgrade their brakes to get under 15" rims.

[John B]

Your wife rocks.

[Silonius]

Originally Posted by John B

Your wife rocks.

Damn right!

Have you looked into getting the new rear subframe? Don't know the part number but it seems like a nice part. I know it helps adjust rear alignment and it might be beefier but I'm not sure.

What is the part number off those wheel studs? I ordered some H&R wheel spacers that came with front wheel studs but I still need a set for the back.

I'm taking baby steps to get my rally Focus

I'm glad the Scirocco will still be up for some rallying too!

Ok, so the cage won't be legal for road racing (Spec Focus) but you could still get it out on track and get some circuit practice. That is my plan at least once we get a new(er) daily driver for my wife and I get a real job.

[mievil]

Originally Posted by BigSandwich

The rally brake kit is basically the brakes off the '06 ST. The fronts are similar to the SVT but a little smaller so they will fit under a 15" wheel and they have rear disks.

This is excellent freaking information. So they fit ANY 15" wheels? (well, any meaning anything we'd normally use?) And there's no other junk to worry about? It's the same as a SVT swap, without the size? Also, please let me know how much this costs. If necessary by PM. Thanks a ton. I was wanting to do an SVT swap just to get the rears, but didn't want to because of the necessity for a wheel up-size. This is really good info for rallycrossers, since the tire issue is still there for us.

Keep the pics coming. This is exciting.

[Angelus897]

Exciting stuff. Keep up the great work!