BOXIN’ CLEVER

The Fo-Cos gets all of its transmission, running gear and suspension reinstated…

Last month we reached a major milestone with the FoCos project, in that we fitted the freshly rebuilt YB engine into its new home. However, as you could see from the photos, the YB might have been in place, but not much else was. No gearbox, no suspension, no rear beam/diff, no brakes. Basically, we dropped the bare YB onto the front crossmember and that was about as far as we got.

So, the target this month was to get the car back on the floor, on its own wheels, and with all the running gear, suspension and brakes all in place. A lot of work, maybe, but both myself and Mark Hudd are pretty familiar with Cosworth-powered Fords, so we already knew what would be needed and had previously started the ball rolling by sending parts out for powdercoating and getting the gearbox and diffs rebuilt. So, this month it was a case of fitting it all back together – still a sizeable task, but a lot more do-able than if we had to wait for all the bits to come back from specialists.

The rear beam was modified to six-degree spec for better handling, then sent away to be powdercoated gloss black. Meanwhile, Pete Doughty rebuilt the MT75 gearbox with heavy duty straight-cut gears and fitted Quaife ATBs to both the front and rear diffs. Mark and I wasted no time fitting it all back to the Focus as soon as it was ready, and we also refitted the Leda coilovers that came with the car (as these look to be in good condition and are already set for track use) while adding adjustable TCAs and compression struts at the front end too.

We even found time to add the brakes as well; AP Racing 4-pots with 330mm discs at the front, with a 300mm big-disc conversion at the rear using the Cossie calipers.

Now that lot’s bolted in place we could whack the wheels on and lower the Focus to the ground for the first time. But it’s not ready to come off the ramp just yet – we’ve just made a start on adding the turbo, intercooler, radiator, intake, and all the other bits in the engine bay. Then we need to plumb it all in, sort the ECU and wiring, and that’s without even making a start on the cabin or the exterior pieces that need to go back on. I’m hoping to have the car on display at RS Combe, although I doubt it will be running by then. So the first time I’ll get to use this on track in anger is looking like it will be Ford Fair – see you there…