DVS LT Vocus XR5 - 93% Volvo content

Finally got the oil cooler plumbed on the Vocus over the weekend.

Here's the sump adaptor that I posted a few pages back in place and mounted -



We simply looped the coolant line back onto itself as we're obviously replacing the coolant cooled sump mounted oil cooler with an air cooled cooler, mounted up front in airflow (and not below the the turbo).

We had the lines in and out a few times as we cut them to length and made brackets to mount them out of the way.

The lines are Aeroquip rubber oil/fuel hose with a black Nomex outer sheath.



On the sump end, we used typical red/blue Speedflow AN10 fittings, as they're out of sight, whereas up-front we used black AN10 fittings so that they're not easily noticeable from the front of the car.





With the grille finally in place, black lines, black fittings and the black intercooler are barely noticeable. The grille is an aftermarket Zunsport grille that we offer, as the original was broken and unusable.





This is the first time in quite a while it's had a grille and front number plate on it.
Finally having a front number plate fitted is great as I'll be more inclined to drive it around a bit more.

Cheers,
The grilles and grey features should have definitely been black from factory. Even when well looked after, the grey just looks faded and horrible.

It's quite the contrast when I look back. Here's a before and after -

With a few other odds and ends eating my time at the moment, I figure I'll get some more bits and pieces organised for the next 'Vocus day'.

The three key things I want to achieve next time its up on the hoist are -
* Weeping RH driveshaft seal
* Replace lower torque mount
* Fit rear camber arms

I am going to add to that a quick rear brake conversion to replace the standard 280mm rear brake setup with 302mm brakes. Much like the front of the P80 when you also move from 280 to 302mm rotors, there doesnt appear to be any more to it other than a difference in caliper hanger and a larger rotor.

I figure I may as well get it done while I'm doing the rear arms.

With rear arms done, it'll be wheel alignment time and then time to get the other wheels and tyres on it.
In the background, I'm working away on a front brake upgrade too.

@Philia_Bear the revoknuckle front end won't fit without a heap of work/cost - probably to the point where it may simply not be worthwhile. The front subframe is very different too.
Probably the biggest issue is that Focus RS wrecks are pretty thin on the ground and new parts pricing will make it cost prohibitive.

Do you mean the Heico branded ATE kit? I have a lot of the part numbers for that kit actually, finding pads for it can be very difficult.
As is standard for anything Heico, after-sales support is poor and getting actual data on it takes some digging.

If you like, I can arrange for pads to be made up - I'd simply need to borrow a sample inner and outer pad.

The 'efocus' mount that is commonly talked about is actually used on local (and european) Mondeo models too (this might also mean it's used on Fusion models in the US. Not 100% sure.).

My front setup is not far off being done. I just need to make a choice between two calipers and (externally the same but mounting differs a little) and tweak my adaptor to suit before doing a small proper production run (rather than hand cut/made adaptors), laser cut and cnc machined.

I've got a customer running a 370mm front setup and another with a 355mm setup (both are Commodore SSV Brembo calipers with a multi-piece hat and rotor) that we made up, however there is a need to fit a under an 18" which neither of these do.
18" wheel means you dont have to run crazy low profile tyres.

sucksqueezebangblow;121536 wrotectsv

Over the 6 spot caliper??? Good luck with that.
Something might exist, depending on dimensions of the inner wheel spokes and final caliper placement and rotor size, I guess, but it'd require some serious thought to package it all.

That might make some sense - that style of wheel (not quite knowing which one) are typically a flat billet face, with very flat inner spokes mounted to a two-piece barrel.
I guess you could do the same with a larger steel wheel.
Rotor size would be critical though.

302mm rear rotors arrived today.
These are Mountune ones.

If you weren't already aware, Mountune are huge in the small Ford performance market and a lot of our local Focus & Fiesta models are available with Mountune options from the dealer, all covered by manufacturers warranty, etc.

Anyway, unpacked them and was a little disappointed that they're actually simply Ford castings with a 'C cut' in them.
Good info to know, but a slotted Brembo option is a better rotor and a little cheaper.

This is a good example of why we buy things in to take a look at before we offer them.

We made some more progress yesterday but also came across a few hurdles as well.

The positives first -
* replaced driveshaft seals
* replaced the lower torque mount/roll restrictor
* fitted adjustable rear camber arms

Here's the Mondeo mount vs the LS-LV Focus XR5 one -



Focus on the right and Mondeo on the left. The Mondeo mount shown is used across a few different Ford models and is stiffer than the standard Focus XR5 mount and should be less prone to failure while being less harsh and have a longer service life than a urethane or solid mount in this application.
It'll be a direct fit for P1 Volvo models too. Commonly, via the internet it is referred to as coming from an 'eFocus' but it's sourcable locally from MA-MC Mondeo.

Also did some playing around with fitting up a 336mm front rotor from LV Focus RS with a large 4 spot Brembo caliper, this was more to validate an adaptor bracket/design though this particular caliper will likely not be what we use in our 'kit' (available in the near future).



It'll work fine, but needs some more thought around spacers to align the caliper.
Factory 18x8" ET52.5 LV Focus XR5 wheels will need a spacer to clear.
Lower offset should be ok, probably around 48mm or so.

The rear camber arms were easy, so not much further to comment about them. Pre-adjusted their length on the bench and then string-lined a rough alignment with the car on the ground. It's close enough until I can get a wheel alignment done in the next couple of weeks or so.