thielt1

I thought I would bring USA build over to the UK forum since I am on here all the time and you guys are experts when it comes to questions I might have about the FRS.

Keep in mind this build has been taking place over the course of three years now, two of which were for sourcing parts.

Where it began:



To Here:

thielt1

Door cards: (I will now be using these as the rears will need to be cut up a bit to fit the cage and I didn't want to have real rs cards sent here only to be cut up. I will be running euro handles with these.)

thielt1

Front Bumper cut off, our bumpers are welded on where as yours bolt up:


New Bumper Mounting Plates Welded On:


Bumper On:

thielt1

Rear Bumper:

thielt1

Car in Rotiserrie for first time because new shop was being put up:

Goodbye Old Shop:

After an Entire Summer of putting it up Hello New Shop

thielt1

Blasted and Primed underside:


This will be primed once more and painted after under coat is on and all cage and harness eye hooks are put into place

thielt1

Blasted and painted all suspension parts being used:

thielt1

Urethane Bushings:

thielt1

Quarters off:

First Fit:

thielt1

Inner Quarter Panels Cut Out: (I eventually had to remove more material then shown)

thielt1

Start of new inner panel:

Little farther:

thielt1

Primed Inners:

thielt1

Rear Strut Bar:

thielt1

Fitment Mock up before welding:

thielt1

Welding:

thielt1

Sanding:

thielt1

Here are the hood vents, I thought for what I was paying for these that they would come in trimmed and matching but I was wrong. These are WRC hood vents made from one of the original molds or at least they are suppose to be.
How they arrived:


Trimmed:

Close ups of Imperfections:


Fiberglass mud so I can even them out:

thielt1

6 Point Cage now Installed:

thielt1

Hood Progress, Die lines:

1st cut made with air grinder and finished with die grinder:

Cut out the rest with 4 1/2" grinder and die grinder:

Both:

Vents sitting:

thielt1

Finishing hood:

Welding in plates:

I might tack to the actual hood surface but not to much as I don't want it to warp.

thielt1

Finishing up hood:


Prepped cage for paint, I don't think I posted a picture of the cage arms yet. These were the ones I had to weld to make this a bolt in cage.

thielt1

Hood just about ready for paint:



Car getting ready to be moved for paint:

Underside:

thielt1

Moving along, Primed:



Cage:

thielt1

Interior and roll cage paint:



RS Rad Fan:

Bottom:

thielt1

Wheels arrived!

Rad Fans Refurbished:

thielt1

If I was flush with cash this would be done! I agree with the weight though.
Not a huge update but I replaced the allen bolts on my cam gears for hex bolts and polished away the massive purple.

I also split my gearbox (3rd synchro was bad when I bought it) I think I am going to change 1st and 2nd gear to the RS spec if I can as they were taller gears.

Matt Baxter

iTrader: (37)

Looking awesome that, will you be running a rs engine?

thielt1

Engine:


Started test fitting the turbo kit:


Here is the parts List for what came with the kit, some things will change:

This kit made 396Whp/372Wtq @ 24psi on 93 octane

TopSpeed Turbo RACE Manifold
Garrett GT2871R Turbo (4" anti-surge compressor housing & T25 Plus v-band outlet turbine housing .63 A/R)
-4AN Braided Stainless Turbo Oil Feed Line (includes all necessary AN fittings and line from block to turbo)
-10AN Braided Stainless Turbo Drain Line (includes all necessary AN fitings and line from turbo to oil pan)
-6AN Braided Stainless Turbo Coolant Lines (both inlet and outlet with necessary turbo fittings/lines from turbo to coolant lines)
Zetec Oil Pan (with -10AN fitting and stat-o-seal washers already installed for turbo oil drain connection - leak free)
TopSpeed 2.5" Stainless Downpipe (v-band - turbine housing to flex pipe)
TopSpeed Stainless Dump Tube (v-band, works with included Tial 38mm MVS Wastegate)
Tial 38mm MVS Wastegate (blue)
Tial 38mm MVS Wastegate Spring Set (all 6 springs, from 4.35psi - 24.66psi)
Greddy Type RZ BOV (grey)
2.5" BOV Tube (Greddy style 2-bolt flanged tube)
TurboXS Manual Boost Controller
Garrett High Density Intercooler Core w/ATP Cast End Tanks
Siemens Deka 60lb/hr Fuel Injectors (4)
Diablo MAFia
All 2.5" HOT side aluminum tubing, silicon couplers, hump hoses, stainless t-bolt clamps (turbo to intercooler)
All 3" COLD side aluminum tubing, silicon couplers, hump hoses, stainless t-bolt clamps (intercooler to TB)
4" Hi-Flow Cone Air Filter (includes 45 degree silicone coupler, tubing and clamps)

thielt1

Thought I would make it to the end without someone posting..........almost.

To my understanding when the RS was being built Ford sent over three test engines to Michigan for ? None of these three were ever put into anything so all they ever saw was dyno time. This engine is one of those three.

thielt1

I recieved an update from my painter today, all parts I dropped off are prepped and primed. Car will be getting dropped off today to get prepped and primed. Hopefully car will be fully painted by next week. I will try and get some pics tonight of the progress.

Also I just located a RS Gearbox and someone willing to ship it!

Both will be sent to Haines Motor Sports Inc for inspection and rebuilds.

Andy Tucker

looking good there mate

Pete frst

Great to see Rs's stateside and yours is looking good,keep us updated

Matt Baxter

iTrader: (37)

Opps sorry,
Looks like a nice project I guess that the focus rs didn't make it over there then? What about the mk2 frs do you get them over there?

thielt1

Neither

The MK2 can't even be built as a replica over here because the platform never made it. The only people have a mk2 over here are Ford Motor company (2 or 3 test cars), Ken Block, and a guy who I think has dual citizenship with mexico.

With the latest focus we might have a shot at a FRS along with you in 2015

-beefy-

iTrader: (6)

where you based in the usa buddy ?


did you go for 9 j team dynamics ?


like dicko put on his ?

thielt1

Wisconsin about 15 minutes from Road America.

The Specs on my TD are 18x8 et35, I didn't want to go with the 9" width because I haven't heard any real benefits on them for track use. Tires should be a little cheaper on the 8's as well.

The 9's do look agressive though!

nevsrevs

top marks mate, is jeepers kreepers behind your work shop? lol

McGoo 69

awesome build im loving the effort youve put in to make this a rs!

thielt1

Thanks for the comments guys!

MK5RS2K

very very nice,keep up the gd wrk