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J5 WTF - Focus focus Focus

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Wed Nov 27, 2019 11:59 pm PostPost subject:
Jackstrath
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Joined: 25 Jul 2012
Posts: 313

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Sooo Winter work is well under way! Long, prob boring read.

For its last MOT i had to do a chunky repair to the Sill, i knew this day would come so after i patched it i decided it was time to put new sills on it.

Sad




Because i have a touch of OCD i couldn't just put new sills on it, i would have to do something with the rear arches, now you can get pattern ford focus rs rear arches as some classic car company bought the stamps from ford, but i decided to go down the route of getting the rear wide arches to match the front. Full carbon kevlar rear 1/4 panels.

Because i was doing the rear arches i decided the underside of the car could do with a bit of TLC so thats where we will start.

So, this is what i was faced with, 17 years old, 80 odd thousand miles of fords finest metal with Scotlands all season roads! Sad



Doesnt look to bad....

Tank dropped.



Small mirical i didnt find any holes



So the long and pain staking process of scraping all the underseal off and buffing all the surface rust off started! it prob took me about 20 hours all in to removed it all, horrible stuff and not fun doing it on your back!



The whole underside was then treated with rust converter.





Dry/Converted


Whole lot was then Zinc sprayed



Then painted with 2 pack expoy



I was going to raptor coat it but i think il just leave it with this, its fairly hard stuff and iv been using it on the wheel wells for the last year and a bit and its still in good nick so i think for the underside it will be fine and saves adding any more weight!

Rear axle dragged out, love how easy it is to drop the whole lot in a 1er!



And although a jet wash would of seen it ok, full strip down was done!



and sent off to Customised Coatings



At the same time the nuts and bolts that didnt round were sent off to get re zinc plated



So due to the wide arches being about 1.5" wider each side, even my plan to run the square 255 set up on the 9J rims all round would leave the rears looking a little lost!

Luckily i can rob bits from the ford racing puma and 20mm axle spacers should work out just fine.
They need a little trim to clear the ABS sensor like so.



I then got the rear axle built back up and mounted on the car.





Which then allowed me to get the rear hub spacers installed and brakes all built back up.



Il need to run new brake lines due to the axle spacers, but il do that when im running new lines underneath.

Can see the beefy spacers here!

IMG_0791 by Jack Strathdee, on Flickr


So that's really the last 6 weeks update! Hopefully in my week at home in December i get a good crack at replacing the sills and then its onto the rear arches!

Thanks
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Mon Dec 02, 2019 9:43 pm PostPost subject:
Matty.H
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Joined: 20 Feb 2011
Posts: 386
Location: The Shire

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Keeping another blue oval alive!!!

Decent bit of graft there Jack. Thankless task cleaning the underside of the car lying on your back.
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Tue Dec 03, 2019 9:54 pm PostPost subject:
Jackstrath
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Joined: 25 Jul 2012
Posts: 313

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Aww matty, it wasnt fun, it took what felt like hours of scrapping that stuff off! getting the stuff as hot as you can (it starts to smoke/burn) makes the world of diffrence to remove it. My cheap £20 ebay heat gun is still going, gobsmacked as i used it to removed all the coating stuff on the inside of the focus, wrapped the motorbike and car with it, and all of that and its still working!
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Thu Dec 05, 2019 11:18 am PostPost subject:
Steve H
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Joined: 19 Aug 2014
Posts: 265

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HOLY FRANK!!! That's a lot of work, good effort. Can looks amazing.

Is the Focus seeing going to be seeing the track in 2020?
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Thu Dec 05, 2019 7:31 pm PostPost subject:
Jackstrath
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Joined: 25 Jul 2012
Posts: 313

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Steve H wrote:
HOLY FRANK!!! That's a lot of work, good effort. Can looks amazing.

Is the Focus seeing going to be seeing the track in 2020?


Its getting there, hoping to have all the work done by the end of feb, then it really could do with another hour or 2 on the rolling road to just tweek the map and it should be good to go.

I want to do a round of SLS and a round of Time attack (an actual round not just a RWYB) but my im not sure if i will be able to with the way the race licences work, i need to upgrade mine but im not sure how far back i can go with Sigs Sad i think over the last 4 years iv only done 3 events ! the joys of working away
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Mon Dec 23, 2019 3:35 pm PostPost subject:
Jackstrath
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Joined: 25 Jul 2012
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So home for 7 days in December! Fun!


So no mucking about got stuck right into it! Took a little longer due to mainly the creating of the side sill where the exhaust comes out. I wanted it all boxed in so it was all nice and strong. Also iv never fitted sill stands before so a few youtube videos later me and my mate Craig were ready to go!


So the sills, when i did my repair from what i could see it wasn't looking good. Pulled the whole sill off, and they actually wernt as bad as i thought they were going to be! There were no holes other than right at the rear in front of the back arch, there was a few crusty bits so decided while we were doing the sill stands replacing the whole lot was the best thing to do while balls deep in it!


Picture of said sill.





Got excited and didn't actually take much photos, will try to remember when i do the other side!

The whole front section was replaced here.



Rear



and all boxed in





So then it was onto the rear arches, RS fans, look away now haha!





Its not all what it seems, they were needing cut out and replaced anyway. And now i can fit the 255's in the rear with room for more if i wanted!

Rear tubs made


Now the RS is already wider than the standard focus, iv added another 2" on to each side!



Gives you a slightly better idea



and the rear arch panel just held in place


and stuck 4 rivets in just so i could do the fit and finish work




So thats it, prob not going to be much updates from now. Away on holiday in Jan so prob wont get near the car until feb ! Sad
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Thu Jan 09, 2020 1:49 am PostPost subject:
Jackstrath
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Joined: 25 Jul 2012
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So hope everyone had a good Christmas and new year!

Back to the broken record that is the focus.

So onto the other side, this was supposed to be the easy side but after grinding away the paint the signs were there that this side might be hiding more than meets the eye. The front part of the sill was no surprise, due to a "off" back in the early days of my ownership the front sill was flattened. I should've gotten it fixed correctly there and then but i was young and dumb! The front inner needed a bit of patch work to return the strength back to it. What was left was cleaned up and straighten out, and if no use cut out.

So this was further down.



Not terrible but when combined with the front section it was decided to just cut the whole lot off.

Bye bye sill


Front section in detail, luckily it didn't go very deep so was all cut out and replaced.





Thought i took a photo of the new lip but cant seem to find it, but as you can see first sill stand fitted



Rear sill stand fitted, That last 15" of sill was actually cut out after this and replaced.


Rear tub, tubbed.



Lower sill made to match the arch.



Love how fat it looks here.


And full sill all fitted and in primer.





So big thanks to my mates Craig and Scotty for helping, non of us are welders, but all love cars and fabbing bits and bobs up, Super pleased all the metal work has been done!!

I'm now away on holiday and then back to work so i won't see the car until February now! But its now on the rebuilt phase so only way is back together which is a nice feeling!

Thanks!
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