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Old 11-04-2010, 09:25 PM   #1
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Default focus rs cosworth 4x4 Floor and arches and Engine bay Painted :-)

thought id try and start my own tread of the build of my focus
bought it one week ago of a guy who started building it and lost interest
since buying it ive made a roll over jig, got the engine and box in and removed the 2wd gearox tunnel and started replacing it wi a 4wd one he car has been fitted with a sierra saffire rear floor pan, ive started to clean it up and stitching the floor pans together.


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Last edited by whizzisat114; 13-09-2013 at 07:19 PM.
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Old 11-04-2010, 09:58 PM   #2
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I can see why they last guy lost interest..... good luck with this one , hope you can get it finished.
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Old 11-04-2010, 10:16 PM   #3
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i have seen this car today and dave has got the no how to do this car . as when i had a look at it he is doing some nice work and has some good plans with it
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Old 14-04-2010, 09:43 PM   #4
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Default Focus cosworth 4x4 rear strut brace 30-01-11

Started to clean off the rust with a wire brush in the grinder and made up some plates to join the focus sill's to the sierra floor pan.

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Old 15-04-2010, 02:39 PM   #5
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havnt seen one done this way before. Good luck with the build

Cheers,Rick
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Old 15-04-2010, 09:12 PM   #6
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well as it was dark when i got to work on the car i thought id start looking at the diffs/drive shafts this is what i found Click the image to open in full size.
some oneClick the image to open in full size.s tried to split the front diff with a 14lb sledge by the looks of it.
i had an old front diff that i can use the case off and made a tool to enable safe and proper removal of the drive shaft/bearing housings
Click the image to open in full size.
Any one know where i can get the info on how to re-build the diffs on a saffie cossy?
any help will be much appreciated
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Old 15-04-2010, 09:19 PM   #7
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In the big blue book mate
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Old 15-04-2010, 09:26 PM   #8
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ow dear mate still front diffs are cheap ,looks like there 3 you fellas down there with these now lol ,i feel left out i'l give beefy ur number before weekend ,he will proply have his tshirt on tho to spot him
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Old 15-04-2010, 09:33 PM   #9
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Quote:
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beefy will proply have his tshirt on tho to spot him

you wont mis him
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Old 15-04-2010, 09:37 PM   #10
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dave ther was 2 diffs with it im sure there was 1 in the boot of the saff looks good fella
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Old 15-04-2010, 09:49 PM   #11
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Yeah Mark i got the other diff outta the saffie ill m8k a good one out of the two
Just need a nice fella on here to tell me where i can find the info on how to over haul the diffs.
Your new car looks the dogs danglies m8 ill be having a good look round that down the pod
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Old 15-04-2010, 09:58 PM   #12
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hi dave come round on satday when im home and you can see wot i mean by the BIG BLUE book it has all the in fo you will ever need to no about cosworths
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Old 15-04-2010, 10:22 PM   #13
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Cheer's Ian ill take you up on that
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Old 16-04-2010, 12:45 AM   #14
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i got them big blue books davidov you dickhead lol
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Old 16-04-2010, 12:46 AM   #15
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[quote=whizzisat114;4852411]Cheer's Ian ill take you up on that [/quote]
i got them big blue books dave you dickhead
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Old 16-04-2010, 05:03 AM   #16
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Know you can look at 2 BOOKS
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Old 16-04-2010, 05:53 AM   #17
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Thanks guy's for the help
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Old 18-04-2010, 07:20 PM   #18
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started to mock up the turbo/downpipe so i could have a look at the steering colum this weekend,
Just got back from central day there was a 520bhp focus cosworth there bloke spent 60 grand on it
dont think ive got that much to throw at mine.Click the image to open in full size.
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Old 18-04-2010, 08:22 PM   #19
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dont need throw 60grand at it mate ,+bet that was the front wd one ? got a text off beefy he got me sill MASSIVE THANKS FOR THAT DAVE ,
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Old 19-04-2010, 06:00 AM   #20
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No problem Dinlge glad i could help
Only joking about the 60grand ill do my best with what ive got
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Old 19-04-2010, 06:02 AM   #21
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Black lines on strut 's are reference for making weld on strut brace brackets.
and im thinking of picking up the centre mount for the wiper motor off the strut brace.
What do you guy's think of that idea?

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Old 19-04-2010, 08:39 AM   #22
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why you removing central wiper mount dave ?
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Old 19-04-2010, 03:36 PM   #23
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ps pm me ur full address mate got them pics an measurments for you and ian
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Old 19-04-2010, 05:21 PM   #24
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removing as engine hits it on way in/out also cant get dipstick out
Pm sent...
Hope the sill works out ok for ya
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Old 19-04-2010, 05:33 PM   #25
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Quote:
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removing as engine hits it on way in/out also cant get dipstick out
Pm sent...
Hope the sill works out ok for ya

ow ryt i see i just cut mine back same as barry did on his ,would email
pics mate but dont now how to draw lines an write on them on pc ,theywillbe winging there way to you mabe be there for weekend just let ian see them to ,and you can pm me if there any other once you need mate

ps il let you no how get on with sill looking forward to finnishing this now ,well as far as im going
with it
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Old 19-04-2010, 05:41 PM   #26
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Yeah yours will be cut back right flush i expect.
where as mine's still running focus bulkhead and pedal box (as i dont want the steering wheel and pedals over to the once side)
im going to pick up the wiper motor mount with either the strut brace or by way of a bolt on mount that ill fab up , not quite dicided yet,
nearlly finished mocking up the sttering colum and the steering rack so ill try and get some pic's when ive done that
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Old 19-04-2010, 06:04 PM   #27
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Originally Posted by whizzisat114 View Post
Yeah yours will be cut back right flush i expect.
where as mine's still running focus bulkhead and pedal box (as i dont want the steering wheel and pedals over to the once side)
im going to pick up the wiper motor mount with either the strut brace or by way of a bolt on mount that ill fab up , not quite dicided yet,
nearlly finished mocking up the sttering colum and the steering rack so ill try and get some pic's when ive done that

its the same as yours were wiper mounts dave if you look ,my colume isn't sat to one side just inch lower than norm but there fully adjustable so
dont mind ,looks like you got the skills anyway mate look forward to update
ps just posted ur pics now
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Old 22-04-2010, 09:01 PM   #28
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started mocking up the steering colum shortened the cosworth steer colum (in the engine bay) and extended the focus (inside the car) was using 4x4 type in engine bay but made up the one at the top tonight its 2wd which is as luck would have it just the right length
Click the image to open in full size.

made some mounts for the intercooler and radiator also
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mocked the gear box mount up, as the car has a sierra rear floor in , the prop fits as it should no cutting for me ...
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Old 23-04-2010, 10:27 PM   #29
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your certainly getting stuck in dave your doing a better job than i would of done
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Old 24-04-2010, 05:07 AM   #30
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Thanks for your comments Mark, Not done much really this week had a load on at work and ive been knackered when i get home but gonna try have a go this week end
How's your car? you found out what give up in the engine yet?
will you have it back together for the next show?
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Old 24-04-2010, 09:03 AM   #31
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its only a bit of surface rust on that shell, going to be a good project! who has the 60k focos?!
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Old 24-04-2010, 12:02 PM   #32
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It was a white one at central day the bloke was from london
it was a proper beast , ex boreham works machanics built it
started making the rear suspension turrets today,ill get some pics on later
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Old 24-04-2010, 01:25 PM   #33
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Nice project, shall be following this
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Old 24-04-2010, 09:22 PM   #34
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started making up my rear turrets today here's the pic's of my progress
Click the image to open in full size.
just tacked together for now
Click the image to open in full size.
mocking them up in the car , getting equal measurements.
Click the image to open in full size.
Click the image to open in full size.
made up a temp strut brace to keep them just where i wanted them, had to cut them back out and chop the backs out after this
Click the image to open in full size.
started welding them in. got a full day of welding tomorrow
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Let me know what you think guy's
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Old 24-04-2010, 09:41 PM   #35
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Top project fella.Im starting to like these focus cossie conversions.
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Old 24-04-2010, 10:38 PM   #36
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Yeah i like the power of the cosworth engine and the looks of the focus
it should be a nice package when finished
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Old 24-04-2010, 10:38 PM   #37
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see you got me pics i sent then dave hope you could work the measurements out ok please pass
them on to ian when you done cheers
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Old 24-04-2010, 11:09 PM   #38
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Yeah they came but i did'nt use your measurments as ive got the saffie cossie floor pan there is the cut out in the chassis where the old struts were.
Ive used your measurements to make the turrents
and fitted them where they look the most original
im not going to weld the intercooler brackets under the chassis but down the side's.
i saw this kind of design on a works car and thought if they do it it must be tried and tested.
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Old 25-04-2010, 09:31 AM   #39
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looking good dave i will have to come round and have a look to see how your getting on iv not done any to my shell for some time now as iv had that much on with work and my 3dr but at last it look like my 3dr is now sorted its just got to go back on the rollers to check all is good . the only thing i have got for it as of late is the rear beam that hold the diff mount up to the floor just got to clean it up and get it on see you soon dave
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Old 25-04-2010, 09:32 AM   #40
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O dave were did you get the tube from
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Old 25-04-2010, 09:32 AM
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