Ford Focus Mk2 [ST] Estate Sleeper - Build Thread
Discussion
Falsey said:
Just an FYI, the bonnet locks on these break very easily if you are fiddling with the bumpers and grills. Only real fix is to take it to Ford for a new lock and barrel etc if you dont fancy prying them open from underneath every time.
Long time since I had mine now but from memory the issue is something to do with the linkage becoming loose or disconnected when bothered and then not engaging anymore.
Good luck with the project though, will be watching.
Thanks for that, I will be careful with itLong time since I had mine now but from memory the issue is something to do with the linkage becoming loose or disconnected when bothered and then not engaging anymore.
Good luck with the project though, will be watching.
Nearly finished stripping the ST engine bay, and then power pack out
Then it was time to get the engine crane out again.
I think there might be a bolt on engine lifting point on the RH side of the head that we didn't have, if anyone wanted to check I would be grateful! So we had the engine crane on the only lifting point which was on the LH end above the gearbox, a trolley jack under the sump on the other end and a trolley jack under each wishbone. Could have done with more than two of us!
And the engine is out!
Next up will be transferring over everything that was hidden by the engine such as; wiring, fuel lines, brake lines including abs pump, heater pipe work.
Then it was time to get the engine crane out again.
I think there might be a bolt on engine lifting point on the RH side of the head that we didn't have, if anyone wanted to check I would be grateful! So we had the engine crane on the only lifting point which was on the LH end above the gearbox, a trolley jack under the sump on the other end and a trolley jack under each wishbone. Could have done with more than two of us!
And the engine is out!
Next up will be transferring over everything that was hidden by the engine such as; wiring, fuel lines, brake lines including abs pump, heater pipe work.
Digitalize said:
I'd personally be upgrading the lights in the barn, probably to nice bright LED ones. Annoys me no end having portable lights like that.
Great project though, looking forward to seeing it done.
The portable lights are good sometimes, but I agree that the lighting is what lets it down. I'm thinking that I might hang 4 or 6 strip lights from the roof. Great project though, looking forward to seeing it done.
TWW said:
Read this from the beginning and think it's one of the best threads here. Such a great idea and takes some confidence to do. Best of luck with it, really.
Is there any chance of a preview of the interior?
Thank you very much, that means a lot!Is there any chance of a preview of the interior?
You're in luck for the interior, just got it. It's a grey/grey Recaro cloth from a base model ST, as I'm not a big fan of leather in this type of car. It will have matching door cards and the dash from the ST. I will also get a set of custom floor mats made up which will be black with a grey edge to match the seats. I will also get the steering wheel retrimed in black Alcantara with grey stitching and a grey band at TDC. Want it to be subtle and OEM style, the grey should match the exterior paint work and fit in with the 'grey' scheme of the car.
Photos to follow
Anything standard (or after market for the standard car) won't fit because of the spare wheel well. The ST doesn't have a well whereas the estate does, which means that it will have to be a custom job. This is one part that I always knew would have to be fabricated specially for me, but luckily I have a guy lined up for it who makes our race car exhausts. He's based just down the road from me in Brackley and his stainless welding is artwork! He does a large variety of projects and knows what's needed based on your volume and visual requirements. He also did the exhaust tips for my Clio 182.
As for looks I'm thinking a turn down just in sight but under the rear bumper, similar to the big diesel Audi style. For performance I think it needs to be 2.5-3 inch diameter and needs to be quiet enough for long motorway journeys.
As for looks I'm thinking a turn down just in sight but under the rear bumper, similar to the big diesel Audi style. For performance I think it needs to be 2.5-3 inch diameter and needs to be quiet enough for long motorway journeys.
Fastdruid said:
That was why I suggested the Mondeo Estate 2.5T, it has a wheel well (the silencers sit either side) and is the same engine.
Ah, I see what you mean. Unfortunately everything I a bit tight on the Focus-the wheel well is tight against the tow bar bracket and suspension sub frame, so no way to get a pipe over I don't think. Have you got a photo of the underneath of the Mondeo?
I'll get one tomorrow. 
sjj84 said:
Great project, this thread is really interesting to read. How many hours do you think you've put into the project so far?
Not including the time taken to find both vehicles, and online research, and evening research about parts etc, just actual man hours working I think we're on about 150. A couple of photos of changing over brake lines, master cylinder, ABS unit, clutch, heater pipes, AC pipes, engine bay wiring, throttle pedal, gear linkage, fuel lines, fuel tank, fuel filler (actually after a couple of hours of taking these off we compared them and the hatchback and estate are different).
I forgot to get a photo of the engine bay in its fully stripped down state, but here is one of the ST bay showing the bits that we didn't use off it-which is basically nothing!
We also needed to get the dash off so as to swap the extra clocks on the dash top and various other electrical parts. It was also easiest to take the front seats out as they will be replaced anyway.
And this is the prepared engine bay, ready to accept the ST engine.
I forgot to get a photo of the engine bay in its fully stripped down state, but here is one of the ST bay showing the bits that we didn't use off it-which is basically nothing!
We also needed to get the dash off so as to swap the extra clocks on the dash top and various other electrical parts. It was also easiest to take the front seats out as they will be replaced anyway.
And this is the prepared engine bay, ready to accept the ST engine.
JackP1 said:
Been reading this with great interest, proper good effort!
Thank you, but there has been very little effort on my part as I'm really really enjoying doing it. It's helped that it's been so easy (no stuck bolts and everything just fitting together etc), but I just love all the work involved including the research. qwertina said:
Excellent project. Will really surprise and annoy some people when it's done.
Having the cars alongside each other must be a great help.
Thank you! I hope it will walk all over repmobiles and be quick enough to worry Porches and the like!Having the cars alongside each other must be a great help.
Having the cars side by side has been great, whilst still having enough room to work on them both. Unfortunately as we strip down one car we have to strip down the other as well so we lose the reference of it. On the plus side though my dad has a mk2.5 Focus estate (but he lives 3 hours away) so I keep getting him to go outside and take pictures of random parts! It's always good to have your dad helping on your car project!
Sf_Manta said:
Bookmarked, really interested to see where this goes 
Any plans for upgrades on the suspension side of things?
Front springs and dampers are from the ST as they went in with the front subframe. I suspect that the estate rear springs will sit it too high and will be too soft. I will initially run it on these though to get started, but will see what else is available. Any plans for upgrades on the suspension side of things?
Hatch back and estate have different rear subframes and suspension set ups so I can't just use all of the rear ST stuff, and the estate is slightly heavier anyway.
rohrl said:
Good project and you're making good progress by the look of it.
I think the Mk2 Focus estate's back end is an unsung piece of design. It's one of those fairly mundane cars whose styling gives it a boost beyond its place in the automotive pecking order. Every time I see one I think "that's a good looking car".
Which wheels will you be fitting to the car?
I liked the styling of the car before I started, but since working on the car and looking at it whilst stationary I have grown to love it. Unlike some cars (including my 182) it still looks good when it's dirty which is a bonus for me as I don't want the hassle of washing it all the time. I think the Mk2 Focus estate's back end is an unsung piece of design. It's one of those fairly mundane cars whose styling gives it a boost beyond its place in the automotive pecking order. Every time I see one I think "that's a good looking car".
Which wheels will you be fitting to the car?
Wheels will be 17 inch steels from a Peugeot 407, as a Volvo V70 T5 owning friend of mine found that they are the same stud pattern, they have a slightly different centre bore though so I'll need some sort of adaptors.
Sf_Manta said:
Maybe worth finding out the spring rates of the ST and having some made up to the same dimensions as the Estate's setup, then it's just getting decent shocks
http://www.dfaulknersprings.com/acatalog/Specials.... would be able to do them.
Thanks for this, I had been looking for someone who did custom springs. Have you used them before? Any ideas on pricing? I've also been told of a company who does custom dampers. http://www.dfaulknersprings.com/acatalog/Specials.... would be able to do them.
The only problem I have is that I don't know the exact spring and damping rates that I want, as the vehicle mass is different to the ST and will have different loads in the boot.
Although I want it to have decent handling, it doesn't need to be the last word in cornering as I have the 182 and 205 for that.
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