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Focus RS Replica/Conversion in Infra-Red!

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88K views 432 replies 84 participants last post by  SuperFlea  
#1 ·
well, I've been collecting and building(yes building) parts for about a year now, and I'm finally set to get moving on this project. I traded in my beater today for a brand new F150 so now I have a reliable vehicle to drive daily while I work on the Focus build. Starting life as a 2003 SVT:

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I used to have a Euro facelift front bumper and 98spec rear bumper, with rieger lip up front.....but someone backed into the front end and it got broken to bits, so I put it through insurance and used the money to buy the last set of RS bumpers from Capaldi.

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So then I had to start sourcing all the other parts. Scouring ebay.co.uk I was able to get the foglight bezels, brake duct vents, front indicators, and rear fog and reversing lights complete with bulb sockets. I got a splitter from Spudo, and a wing from Cayse. Then I hit a wall, not being able to find sideskirts or fenders and quarterpanels, I had to get creative.....

An opportunity arose..... a fellow member here doing an RS conversion had obtained a set of RS skirts that were damaged....I messaged and offered to make all the repairs for FREE, if he would just pay shipping to me and back with the aggreement that I would be allowed to make a mold of them....and to my pleasant surprise, he agreed!

Here's a link to that journey (quite a learning experience)

http://forums.focaljet.com/euro-rs-...euro-rs-conversion/647178-repair-some-beat-up-rs-sideskirts-nzwnrzs-skirts.html

So I still needed fenders and quarterpanels! About 6-8 months go by of me searching for these.....my gameplan was to obtain a set and make molds like PUMASPEED has in the Uk, they sell fiberglass replicas of the OEM panels for conversion purposes.....but then something incredible happened. I recieved an email from a member here, that he knew of a fellow up in British Columbia that had a complete set of molds (besides sideskirts.....weird, that's what I made!).....he had fenders, quarterpanels, and both bumpers molded from OEM stuff and was willing to SELL THE MOLDS!!!!!

I got in contact with this gent, and we negociated over numerous emails until we settled on a price. MAN, was I a happy camper! what a huge savings in time and energy not having to source panels, then make molds!

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So here they are all unpacked:

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bought a 50" wide roll of fiberglass, 80yards long to make all my parts

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So I'm going to get started over the weekend setting up the molds and begin fabricating the front fenders and Quarterpanels, I figure I can have the front clip finished, painted, and mounted in the next week or two time permitting.....Then I'll have to clean out my garage and pull the car in to remove rear glass and start working on the rear quarters. I have a concept image I made in photoshop but I can't find it right now, I'll have to post it up later on......

Thanks for reading!
 
#3 ·
I can't wait to the progress on this.
 
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#10 ·
yes I certainly do, I know lots of you guys have been waiting on the splitter, I've just been way too busy.....in fact, I may not get to update this thread for about a week now with any new progress. :(

when I start laying fiberglass for my parts I'll work on the splitter while I wait for my parts to cure
 
#11 ·
don't get your hopes up just yet....haven't set any fiberglass in the molds....but these are my concept images I whipped up in photoshop....couple different wheel options...

Stock RS wheels, painted gunmetal (probably won't be able to get a set, and they are 18x8...I want wider)

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17x9 SC replica Mustang wheels in 4x108

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Other wheel I'm considering but haven't PS'd is 03 cobra reps in gloss black.....same basic 5-spoke pattern as the SC's, just they are slightly concave right to the enge where the SC's have a lip....so It's basically a decision on whether or not I want wheels with a lip/dish.....and the comparison against the RS stock wheels is sufficient to make that decision. Open to opinions on this as well....
 
#15 ·
took most of the front clip off.....I'm saving a step here becuase I previously already modified the steel bumper to fit the lower profile euro bumper :)

I'll get the sideskirts and fenders off sometime later this week.

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#17 ·
I'm darn sure going to try to get to FR'13. I try to alternate each year doing a car event and doing a motorcycle event....this year I'm taking my '75 CB550 cafe racer down to mid-ohio for Vintage Motorcycle Days, so next year I'm planning on a doing a couple Focus gatherings....probably Spring Into Focus and Focus Rising
 
#18 ·
Got the sideskirts and fenders off today, and confirmed my suspicions(sp?) that this car was in at least one wreck unreported to carfax....

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Passenger fender is a Keystone replacement part....

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#19 ·
not a huge update, but I ordered what I think is the last of the detail peices needed.....

fender markers

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bumper markers (I already have amber ones, and clear fender indicators.....going to try both colors and see which I like more)

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RS replica grill (I might be a dick and mold this too, HAHA)

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"RS" grille emblem, this isn't a true focus RS emblem, just generic....I'm thinking driverside centered at the edge of the grille to be different)

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Then three of the red ones of these:

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one on each glossy area of the door (pillar), and one on the tailgate

I'm planning to whip up the CF front splitter this weekend/week using a beat up used splitter I snagged as a template. After that I'll make front fenders and paint the front bumper/fenders and get the front clip on.
 
#21 ·
Removed the rear bumper, crash foam, and SVT wing today

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Going to start making the front lip mold tomorrow for a CF splitter. I'll post progress on that as I go. Late next week I plan to set up the front fender molds and lay my fiberglass for those, so maybe in two weeks I'll have the front clip finished. I did a practice mold out of cardboard and came up with a pretty awesome way to make them if I do say so myself.
 
#23 ·
Great to see some progress Nick. Saw you had your rear wing FS so I came running here to see if you made a huge update :what::lol:
In any case, take your time and do it right the first time right?
Keeping a close eye on this thread as I am super excited to see how your fabrication talents expand to panels and what not; as you know I am really happy with the piece you made for me and I'm hoping to buy more of your work as it becomes available down the road.
Keep up the good work!
Regards,
--chaz
 
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