Mk1 Ford Focus RS

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MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
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Hello Folks

Decided to start a thread to show my Mk1 Focus RS and the work I have done to it over the last couple of years.

The story starts when they first came out in 2001 / 2002, I was a big fast ford fan and had been looking forward to the unveil of the new RS for a long time, the first review I saw was on top gear and I was blown away by how it looked and even with all the bad press it received at the time for its way ward handling I knew that I had to have one.

Fast forward 10 years and I'd been to Uni, got a job and bought a flat, but still didn't have an RS. My current Focus TDDI was beginning to cost me money and while I was offshore my mother advertised it and before long it was gone and I was forced to use my 110 defender as a daily. A couple of weeks went past and I was looking through the classifieds and the last advert in the ford section was "RS Focus", I would normally have stopped looking once I got past the Focus's but it must have been fate for me to read on and find it.

I went to see it that day and a deal was done, this was probably my first mistake buying the first one I saw but I will come to that later haha.

2 weeks later and I headed North of Inverness to pick it up. The drive back home was awesome, I got to the Tore roundabout again still North of Inverness and it was the first time i felt the diff working, being pulled towards the apex was such an alien experience but exhilarating at the same time. I had to wait another ten miles before there was another decent corner to feel it again haha.



It was a fairly standard example, with the only mods being different brake disks and a couple of stickers, but it had quite low mileage and was on an 04 plate which made it quite rare. I didn't know this at the time but there are less than 30 in the UK on 04 plates.

From there I had 2 years of using it as my daily driver and enjoyed every minute of it!

Eventually the bodywork began to bubble on the rear aches and the bot lid so I took it to my bodyshop to get that fixed which was successful initially but unfortunately it wasn't to be a permanent cure, my friends eventually started to make fun of my car that would need an annual paint service!

2 years later at the same time as the rust re-appeared I also ended up working abroad for six months so the focus was left in the garage and forgotten about or almost forgotten about! I began preparing for refurbishing the car when the time came. This included buying new standard suspension and new genuine steel front wings which were ridiculously expensive!!

On my return I put the car in for an MOT and the true extent of the rot was revealed behind the side skirts





Edited by MK1RS Bruce on Monday 18th March 22:14

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all





MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Based on the above pictures and the fact that the car had sentimental value to me the only option was to strip the car down cut out the rot and weld in material then rebuild it back up with new components.

Had I known the cost and time it would take I might not have been so keen to do this but once you start you are committed and have to follow through with the work.

I managed to find a bodyshop who were willing to take on the work and fit it in around the insurance jobs that was their bread and butter. They had recently completed an original Audi quattro and their quality of work and skills looked good, they had to make new wings for the Quattro so I was fairly sure the new rear wings I needed wouldn't be an issue for them.



First job was to strip the car down to a shell and begin cutting out the Rot, the above pic shows the rear arches both inner and outer being cut away to add in new material.



Then the old sills were cut off and new ones trimmed to fit. A lot of the original RS parts don't exist anymore so it was very much a case of make new panels for it from scratch or from normal focus panels and modifying them to fit.



Finally the engine and subframes were removed and it was attached to a spit to begin the rebuild works.

Edited by MK1RS Bruce on Monday 18th March 22:20

budgie smuggler

5,384 posts

159 months

Monday 18th March 2019
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Nice! Following. thumbup

r5kdt

246 posts

185 months

Monday 18th March 2019
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Looking forward to this , owned 4450 from new until divorce forced a very reluctant sale... I think it is on R5 BVM now if anyone knows its wherabouts. Cracking car if you didnt mind the Quaife!

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
r5kdt said:
Looking forward to this , owned 4450 from new until divorce forced a very reluctant sale... I think it is on R5 BVM now if anyone knows its wherabouts. Cracking car if you didnt mind the Quaife!
The Handling characteristics of the diff is one of my favourite aspects of the car! Yes it feels like its trying to kill you but if you relax your grip a little you soon realise it never pulls you far from your chosen path and it always feels like its trying to seek out ever last bit of grip!

A very forgiving car too, I remember coming up a slip road once, going too fast obviously! I stupidly lifted off slightly and the back end came round on me probably to about 45 degrees but I buried the throttle and she straightened up luckily.


MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Once the car was on the spit we decided the best way to sort out the underside was to blast it. The bodyshop constructed a ply wood blasting bay in one of the workshops and two of the guys spent a morning cleaning all the surface rust and old wax oil off the bottom of the car and the underside of the arches, One of them blasting and the other one shoveling grit into the blasting pot haha. The it was into the paint bay immediately afterwards to get it primed before the surface began to corrode.

Underside


front arch:



Engine bay:

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Post Blasting any steel that was thin or rusted through was cut out and new steel welded back in place.



the most of the work was around the rear arches.





At this point it was pretty demoralising being around the car as it seemed to be continually cutting parts out to replace them and the end was far from sight, this was partly down to the body shop refusing to cut corners so hopefully once its all done I shouldn't have anything else to worry about ever again, the car is not going to be a daily after this and probably won't see rain unless I get caught out haha!

r5kdt

246 posts

185 months

Monday 18th March 2019
quotequote all
MK1RS Bruce said:
r5kdt said:
Looking forward to this , owned 4450 from new until divorce forced a very reluctant sale... I think it is on R5 BVM now if anyone knows its wherabouts. Cracking car if you didnt mind the Quaife!
The Handling characteristics of the diff is one of my favourite aspects of the car! Yes it feels like its trying to kill you but if you relax your grip a little you soon realise it never pulls you far from your chosen path and it always feels like its trying to seek out ever last bit of grip!

A very forgiving car too, I remember coming up a slip road once, going too fast obviously! I stupidly lifted off slightly and the back end came round on me probably to about 45 degrees but I buried the throttle and she straightened up luckily.
I was fortunate enough to get up to Gaydon as they had delayed production so long they offered the people that had kept deposits on an opportunity to get out with test drivers in a couple of preproduction left and right hand drive cars, they said exactly the same thing let the car do what it wants to do, do not correct it and it it will steer you where you want to go. lots were written off in the early days with people being too enthusiastic with their steering input.

God those ford "sparco" seats were uncomfortable though lol....

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
r5kdt said:
I was fortunate enough to get up to Gaydon as they had delayed production so long they offered the people that had kept deposits on an opportunity to get out with test drivers in a couple of preproduction left and right hand drive cars, they said exactly the same thing let the car do what it wants to do, do not correct it and it it will steer you where you want to go. lots were written off in the early days with people being too enthusiastic with their steering input.

God those ford "sparco" seats were uncomfortable though lol....
I think the original pilot sport tyres were pretty poor and didn't help things either, Mine was and will be running michelin pilot super sports, they seem to suit the car quite well. Just got to hope that it handles as well when I get it back together as it did when I took it apart haha!

Yeah they are not the best, long journeys and they kill my back!

I honestly don't mind the interior but it is difficult to defend it against criticism, however the thing is I never think oh god this interior colour scheme is terrible when I am driving because the experience is so rewarding in other ways.

Petrol_fumes

219 posts

211 months

Monday 18th March 2019
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Excellent work OP.

This is exactly the sort of thread I hope to find and adore reading.

Poynter87

125 posts

129 months

Monday 18th March 2019
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You have obviously put a lot of time and effort into making the car nice again. The mk1 focus rs is a very fun car to drive, I've had mine 8 years now and I still enjoy driving as much as I can though it needs a bit of bodywork doing. Keep up the good work.

anonymous-user

54 months

Monday 18th March 2019
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Jeez, these threads on people "restoring" their RS's make me feel old, as i was part of the team that developed the car!



AP3 (Attribute Prototype 3) on Stevlio pass, way back in, umm, 2002 i think. #nowanoldgit


Good to see people looking after their RS's though, and values are on the up :-)



AndrewEH1

4,917 posts

153 months

Monday 18th March 2019
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Max_Torque said:
Jeez, these threads on people "restoring" their RS's make me feel old, as i was part of the team that developed the car!



AP3 (Attribute Prototype 3) on Stevlio pass, way back in, umm, 2002 i think. #nowanoldgit


Good to see people looking after their RS's though, and values are on the up :-)
Any more pictures?! Perhaps even worth of it's own thread it you've got some stories to tell

SiT

1,163 posts

201 months

Monday 18th March 2019
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Wow that's a 'proper' build thread if I ever saw one!!!

Great read and what a fantastic project.

Si

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Max_Torque said:
Jeez, these threads on people "restoring" their RS's make me feel old, as i was part of the team that developed the car!



AP3 (Attribute Prototype 3) on Stevlio pass, way back in, umm, 2002 i think. #nowanoldgit


Good to see people looking after their RS's though, and values are on the up :-)
Did you ever think when you were doing the development that there would be people like me who would see the car on release and aspire to own one and probably never ever sell it?

Not sure which parts you were responsible for but thumbs up from me, you absolutely nailed it!! Love it!! The way it drives and handles is unbelievable, looking forward to getting it back on the road shortly!

Edited by MK1RS Bruce on Monday 18th March 22:23

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Petrol_fumes said:
Excellent work OP.

This is exactly the sort of thread I hope to find and adore reading.
Thanks, I have lots more pictures to post, hopefully you will enjoy the journey

MK1RS Bruce

Original Poster:

667 posts

138 months

Monday 18th March 2019
quotequote all
Poynter87 said:
You have obviously put a lot of time and effort into making the car nice again. The mk1 focus rs is a very fun car to drive, I've had mine 8 years now and I still enjoy driving as much as I can though it needs a bit of bodywork doing. Keep up the good work.
Yeah I don't need to tell you how much fun they are and how special they feel. hopefully its as good to drive as I remember!

soad

32,894 posts

176 months

Monday 18th March 2019
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Subscribed. Well, bookmarked the thread. cool

jonnyconnor

165 posts

143 months

Tuesday 19th March 2019
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Really looking forward to following this thread, best of luck with the restoration. I’ve owned 2350 since 2016 and used to own 3304 from 2008-12. Very capable cars with a great personality, they get under your skin!

Mine will be coming out of winter hibination soon and I can’t wait to enjoy it again!