Rear Engine Focus RS Build
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After all that effort, waster

Paul

I seriously doubt it!

Well that’s a shame Steve.

O well no doubt your moving onto something else just as mad...

Would of been nice to see the thing wheelie at least once though.

Not to sound like a vulture but I'll adopt a few bits off you.

Pm’d

Si

I drill holes in everything..!

I thought I'd take a bit of time to update this

Got as far as selling the wheels, before I thought better of i and have been very slowly trying (and failing at times!) to get the project moved along.

Hes a few pics of where its at now.

got some force racing wheels, and some bright paint



and a new engine is currently being built up to go in. Im glad I had S.C. build the ecu loom with the MAP sensor now!




and I'm in the middle of changing the parcel shelf/firewall to carbon, as the ally rattled and vibrated like hell!


I do have an issue with the driveshafts, as on the only real run I managed with the old 130bhp engine they snapped after changing out of 1st gear. So as much as my wallet isnt going to like it im going to have try to source new custom ones to cope with the expected 330-350 bhp!??

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

May I ask, how much did the RS engine set you back? As has been said, I can't believe I missed this thread, but it is getting on for 4 years old!

Bare engine was a £grand, Turbo free, Throttle bodies/Plenum/Injectors £75 all in, Manifold £350 for a favour (normally well over double that!)

The rest of the little bits were robbed off the old engine

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Nice one, its good to see that its not been broken!

If you need some custom shafts, try brand engineering in Birmingham, they do ALOT of bespoke stuff.

https://www.facebook.com/pages/Fusion-Fabri..._homepage_panel

www.fusionfabs.co.uk



1/4mile in 13.2sec @ 111 terminal on 15psi

keep going mate!

I'm so glad that you're going to see this through. It'll be an immense car.

In the 13's at last!.. Just

too right, cars like this need to be kept going, its truely a piece of engineering, have a word with a few guys on here, i'm sure they can help you with drive shafts.....

"Cars are a lifetime of pain"

Any new updates on this monster?

So glad you kept it going

A bit, I'm slowly coming to the realisation that throwing it together for Avon each year isnt the way to go.

So ive started remaking the bits im not happy with. Made a new ecu bracket and fitted both side 'parcel shelves' yesterday. Plumbed in the vac system to the Throttle body setup, fitted the MAP sensor to a new bracket.

Ive also made a template so I can make the door skins and rear quarters from carbon. Looks easy, so will make a panel next week and see how it looks. I want the structure of the steel door to avoid all the annoying problems with that, but will re-skin the door with 0.8mm of carbon, leaving the steel body of the door to support it.

Also put the KAD brakes up for sale, to allow me to up the disc size to make sure it stops!

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Okay, so I sold the KAD Brake setup.

And with some help from Mr Wakely Ive now got these



Disc bells have been drawn up, and the 7075 billets have been ordered, ready to make them.

Ive just finished trimming the ECU Bracket aswell




Also stripped the old engine of the gearbox and clutch, got to swap the flywheel over, then sell a limb to pay for the clutch kit.

I'm also planning on switching the fire wall to carbon. But it's a big sheet to make in one go, and isnt convienient to move around. So the new plan is to make it in two bits, that joggle together hiding the join. This should also make it a bit easier to fit, as in one piece its a pig to flex into position.

Thats all for now!

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

whats happening with the driveshafts?

"Cars are a lifetime of pain"

Nothing at the minute, the welded ones are on the side in the garage. I'll most probably do them last to be honest!

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Been a struggle to get out to the garage with a 1 and 3 year old terrorising the mrs. But managed to get a few bits done in my lunch hours!

Had a go at a set of Carbon door skins



Had this idea in my head for quite a while, and had to know what the gains would be. Whilst the new skins fit, and sit flush with the outer skin. Its just doesnt have the weight saving I was after. Its has the "Carbon" factor, but thats not what I'm about. But I have a new plan, I'll take a mould off these before completing, and selling them. Its all about learning I suppose.




As I cant weld, there was only one way I was ever going to make a new alternator mount!



Made a top mount aswell.





Also had a go at a new throttle stop for the Inlet. Fits great, but may have to remake if it flexes too much, as its bloody light!



Drilled and tapped the inlet plenum for the Air Temp Sensor




Also started looking at the feasability of fitting coil-on-plug. The RS lads seem to swear by the standard ford setup, even for high BHP setups. So I may abandon the idea, although it does look good!?

Disc bells and Caliper brackets are in progress. Ive also started fitting the flywheel/clutch setup ive sourced.

The next project is the crankcase oil breather. there seem to be 2 ways to go. Standard catch/flame trap with a modified breather setup, or a totally custom idea. I'm looking at a way of making my own version of the two!

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Thought I'd update this, as progress has been slow lately.

My clutch and flywheel are fitted.

I've plumbed an aeroquip fitting the Sump for the oil return, and fitted the oil feed.

Also made a carbon, baffled crankcase breather. Just got to trim it a bit more, and fit a b/head fitting and that's done.

Disc bells and calliper brackets have arrived, sending them over to get hard anodised before bolting the wilwood 10" discs and wilwood callipers.

Here's the crankcase breather

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

The carbon work is amazing, have you ever thought of making batches of things?

Drives
-Ford S-max Mk2 Ecoboost
-Rover 100 VVC #2 - track project

Searching is all you need on TurboMinis

Of course, but very few people realise the work and cost involved in most projects. Plus I struggle to find the time!
I have done a-panels, Bonnets, rocker covers, and oil cooler shrouds before though.

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Had a spare hour, an engine crane, and a 2 year old to help.

Its in!



Was real worried whether the plenum would clear the frame, and it does.





Now the car is unwrapped and in the garage for the first time in a year, the winter mods can begin early

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

Good stuff, time to crack on!

Excellent, glad to see this is still being worked on.

always a good feeling when the engine goes back in

Oh it will be coming back out!

This was a means to an end.

Got the car into the space the engine was occupying , allows me to prefit some other ideas I've been having, and to mockup the Intercooler placement.

This is FORD country, on a quiet day you can hear Vauxhalls rusting.

I quite like this, some good work gone into it!

First issue hit tonight.

Had a top mount alloy wrx intercooler for a while. After I had the idea of mounting it into the engine cover, and ducting down off the roof vent. Not going to work, doesn't really fit.

So tried the boot space


It sort of fits, the outlets line up, but it doesn't look right. Going to see about sourcing a long intercooler like a sierra cosworth one???

Also templated the back piece of parcel shelf, will cut it out tomorrow.

This is FORD country, on a quiet day you can hear Vauxhalls rusting.