Gaunt596's Open 2WD Focus Rally Car Build

So, since this dosent really fit in with the theme of the GRM forum, im homing this one here instead. also because the GRM forums suck and lack a lot of features i want.

After having the rear subframe on my 1999 Chevrolet Cavalier literally start falling apart at an event, i set out to look at a replacement car, that isn't full of rust to replace it and eventually build into an Open 2wd Light Rally car. I settled on finding a Ford Focus, since IMO subarus are too generic and everyone runs them. After searching for a few weeks, i found a 2000 Ford Focus ZX3 with 200k on the clock, with a broken master cylinder. Originally listed at $750, i stole it for $300 since the seller really needed it gone to make room for other projects. Here it is the day i brought it home.




Since then, i have replace the master cylinder with a new one, and bled the shit out of the clutch. This is where im at now, and kinda stumped. I know the clutch is good and has life left in it, but no matter how much i bleed it, the clutch pedal only has half of the travel its supposed to have and just barley disengages the clutch all the way. not sure why its like that but at least its mobile for the moment.

 

Currentlythe running the car in SCCA Rallycross , in the Prepared FWD Category, which allows limited modifications to the car.

Another new plan of attack after the first event, also adding in a completed mods list.

Completed mods (In no particular order)

Metal SVT Shift Tower
SVT Front Seats
CG Lock
4-1 Stainless Race Header and flex pipe
Skidplateguy Skid plate (which i realized dosent fit with aftermarket headers, oh well)
Massive Speed system rear disc conversion kit
Gator Axles Upgraded CV's
EGR Delete
Kuhmo R700 Dirt Rally tires on OEM alloy wheels

Planned mods (subject to change often)

93 Octane Tune
Cold air intake/Prototype snorkel
Custom Exhaust from the flexpipe back
KYB AGX Shocks and some sort of rally appropriate spring
Fix all the broken lights
Custom clutch master cylinder (since the OEM one is a real bitch to bleed)
front and rear strut tower bars
poly bushings everywhere
battery relocate
AC Delete
Power steering cooler and custom lines

 

your exhaust pipe looks out of place

 

yeah.... thats actually the factory exhaust... it does feel like ford kinda forgot about the last 12" of the exhaust until the last minute

 

this was my first car. 2000 ZX3 auto. I did a catback exhaust, short ram intake, and full stereo upgrade. Then I realized I wanted a manual.

 

Yup. The Taco was my first car, but i realized i needed a go fast car, but still wanted to play in the dirt, so rally car i went. this is a Zetech with a 5spd. it makes me want the 6spd in my taco

 

My current Taco is my 2nd auto. Ive had the focus, an integra, an Element, WRX, 5 lug 2wd taco, another Element, and current real Taco. All others have been manual. I miss it.

Also, please get this spoiler. I always wanted it for my focus. Hah!

 

Yes, that spoiler is 100% in the cards. i cant run it in Prepared FWD because its not a "Factory" part even though ford designed it for their WRC car. Also... that spoiler may or may not have been the real driving force behind my choice of car

 

you and my 16 year old self think alike!

 

I just sold all my rally cars. If you cage it you will be pushed into mod. Not impossible to be competitive in rx with a stage car though.

 

Soon this will be you!

 

yeah, a full cage wont be put in until we go to actual stages, but i will put in a roll/harness bar and racing seats/harnesses in the event we do flip the car

where was this taken? that look an awful lot like one of the DC region guys, although i dont recognize the blue van

 

This is gnarly! Glad to see you starting a rally project! Best of luck boss.

 

It was in Sterling VA. On 28 south. A few years ago. The mirror is my ZX3 mirror lol

 

Well, the cavalier was the first but it has hit a wall

Hmm. Wonder if that was kimmett before he got the new van and dedicated rally car.

 

Long time no update. The 2016 season ended for Rallycross, i missed being the SF season champion because i babied the cavalier on its first run... i was 18 seconds off of the lead, and that was how far behind i was on the first run. on the upside, i rode the guys ass all day long, and beat his times the rest of the runs, so i can drive the car hard enough to be competitive. now that were in the off season, things will start moving as ive got two months to prepare the focus for the 2017 season in PF. the motor that is in the car has been abused, and by the amount of leaks in the cooling system, i believe has been removed from the car in a halfassed way. so the plan is to swap in a lower mileage junkyard engine and redo the entire cooling system, along with fixing any other surprises that i find along the way. Im Updating the OP with the newer build plan, since realistically this car probably wont live to see the stages, i pushed the cavalier so hard at the last event that i bent the unibody and got all 4 wheels off the ground.

Ive also got to diagnose the clutch issue i have. i replaced the master cylinder and bled the shit out of the clutch, and its still not operating like it should, ive got less than half the pedal travel i should have. ive heard that supposedly you have to bleed the brakes, then the clutch since its a shared resivior.

 

Moved the car over to my workspace today, will start wrenching on it once the light comes back. let the mods begin

 

Oh Boy. sometimes i wonder why i bought this thing, good lord its full of problems. after getting it up in the air today and inspecting it, i basically have a rolling shell with a motor and trans in it, and thats about where it stops. Im updating the Op with the new plan of attack, but its really doubtful that we will make all the races this season.

 

Also, since , heres some pictures of the car in its new parking spot

 

the parts hoard has begun!