Morning all,

Quick history, I am building a new ED rally car. I have previously rallied one but I did the conversion with a few friends over the course of a weekend and it only lasted 3 seasons before I broke it

So after running Several different rally cars over the years including a EVO and Rolla I decided to build a ford from scratch with all the rally toys.

After working on my ED for some time I realised I should start a build thread, so far I have already had the roll cage fitted and started work on relocating the fuel tank from under the car to inside the boot and currently I’m working on the front suspension and brakes.

At this stage iv got a mix of ED,EF,AUII,BA & FG parts for the car so she is definitely going to be a little different to the normal ED.

Also Feel free to follow me on facebook http://xerxas.com

Current Parts list.
https://docs.google.com/document/d/1onqLQ3Hb2xcGt5l3TX4Uqrs36McuFQNjbVKZYMOQJD8/edit?usp=sharing

**Edit - Typo's and Added Parts list link.

Last edited by XerxasJade on Tue Aug 11, 2020 12:40 pm, edited 2 times in total.

The Build started in February 2019 with a really clean donor car, managed to pick her up for under $1000 bucks and did a whole heap of kms in her as a daily before deciding to do the conversion.







**Edit fixed photo Links**

Last edited by XerxasJade on Thu Aug 13, 2020 12:12 pm, edited 1 time in total.

Striping began right away.

I had a prearranged deadline to get the car striped by so that it could go to the cage builder, part of the arrangement with the cage builder was that the seat rails for the racing seats would be in before I sent the car to him.

Stripping

Stripping


Test Fitting Seat rails (Drivers Side)


Working out Pedal Postion


Finished Seat Rails


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Last edited by XerxasJade on Thu Aug 13, 2020 12:14 pm, edited 1 time in total.

In April it went for its Cage, The cage is built to National Rally Speck with a couple extra bars at my own request. Walker Chassis did an amazing job and the cage came out amazing.

Walker Chassies
https://www.walkerchassis.com.au/













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Last edited by XerxasJade on Thu Aug 13, 2020 12:19 pm, edited 3 times in total.

More Recently, I have been working on removing the rear wheel well for the spare and relocating the Fuel tank inside.

I have also started on the Front suspension and brakes, the rear is coming along resonably well but I dont have many photos of it yet and the front is waiting on my suspension to arrive.

While I have been waiting on my suspension I have been cleaning up all my Control Arms, Knuckles, and Wheel Arches ect.

Cutting the rear out




Wheel arch before


Wheel Arch Primed


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Last edited by XerxasJade on Thu Aug 13, 2020 12:21 pm, edited 1 time in total.

After putting on three coats of primer, I then added a couple of coats of black and finished it off the textured black stone guard, hopefully this will minimize chips so I don't have to repaint it as often as the last car. I haven't decided how i'm going to do the liner yet but it will be some sort of rubber rather than the factory plastic.

I also cleaned up the new AU Stub Axles, EF Drum plates & Watts link bars so that I could paint them.
The AU stub axles in particular came off a wreck and were pretty bad, I forgot to take before photos, but i'm really happy how they came up.

By replacing thew ED Brake plate with the EF one, I don't have to use the ED calipers with the integrated hands break and can use later calipers which are designed to have the separate drum handbrake and just delete the entire cable handbrake completely. This will make changing pads significantly easier as I don't need to screw the piston back in like in the ED ones.

The later model calipers are also a lot more reliable and easier to rebuild so its a win win.

Running the AU Stub's obviously allows me to run AU Hubs, Floating Disks and the AUII Twin pots which will give me a lot better pedal feel and also are a lot easier to change and also easier to get parts for. I particularly like the floating disks and hub setup which will be a lot easier to change at an event in the case of a failure than the ED ones with integrated bearings.

In a perfect world Id go and get a set of BA brakes but we have a 15" control tire so anything bigger than the 185mm disks off the AUII wont fit under the rims.

Finished Wheel Arch


Drum plates, Stub Axles & Watts link Bars


ED Brake Plate - Rubbish


ED Rear Caliper with integrated Handbrake


ED Rear Caliper from a different angle



EF Rear Caliper off a wreck for test fitting.


**Edit Fixed Photo Links**

Last edited by XerxasJade on Thu Aug 13, 2020 12:25 pm, edited 1 time in total.

Nice write up mate. Looking good

bugga! ... lost the pics


did look awesome tho. any chance of em back?

I didn’t realise they wernt working, they look fine my end, I’ll check it out tomorrow.. probably a permission issue on the hosting site, easy enough to fix.

Thanks for the heads up.

My wheel studs arrived today, so while on lunch I pressed out the factory length ones and replaced them with the long ones.

Factory Wheel Studs are 51.5mm long and with the mags that I run (In the photos at the top) they end up well inside the recessed holes on the mag and are super fiddly to start without cross threading.

I realize that for a lot of people this may not be a issue worth doing anything about but for me when you might change anywhere from 4 to 8 tires at a large event it drives me insane.

So to help with this I have gone for longer studs that are instead 73mm long.

I also finished cleaning up my upper control arms and got them ready to paint, I added the Ford part numbers to my parts list noting which side of the car each was from because knowing me I will have forgotten by the time I got to put them back together.

Upper Control Arm


New Hub with Factory length Studs


Stud Length Comparison


New Hub with long Studs


Hub Fitted to Stub Axle

wheel arch looks clean as......






not sure why you had problems chucking pics up as i do my pics thru imageshack as well. i just use the Hotlink for forums: link, copy the link then paste.


keep up the goood work tho.


Cheers

So its been a little quiet the last few days on the car front. Because iv been waiting on some good weather to finish cleaning up my lower control arms.

However while I was waiting I got most of the parts to rebuild my calipers. as well as the Lower Control Arm bolts, nuts and caliper attachment bolts that were on back order from from Melbourne.

So hopefully this weekend I can start on the caliper rebuild, assuming the guide bolts arrive in time.

Also I had a little present from MCA Suspension (aka Murray Coote Automotive) in the form of my MCA Gold Suspension, so now I have some extra motivation to get the K Frame in.

I don't think ill have any more updates for a couple of weeks as until I get the lower arms cleaned up and the new Nolatane bushes pressed in there isn't much for me to do other than fiddly body work which is pretty boring.

Lower Control Arm Bolts - Part Numbers have been added to parts list.


MCA Suspension


Custom Spring Rate King Springs