DVS LT Vocus XR5 - 93% Volvo content

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.

The rear brake upgrade should have been fairly simple - and it is - but I confirmed that an LV Focus RS rotor will not work, as I originally expected it would.

The upgrade is sees a change from a 280mm rear rotor to a 302mm rear rotor, while the RS rotor is the correct dia and stud pattern, the hat is too deep, by about 11mm - this makes sense when you think about it as the RS is wider in its track, but uses many of the same rear suspension components.
The hub face is further out, but the caliper remains in the same place, therefore the RS rear rotor is deeper than the one used on LS-LV Focus XR5 and Volvo P1 models.

Here's the different caliper hanger. New style for larger rotor on the left and existing on the right (as per P1 Volvo and LS-LV Focus XR5) -



And below, on the left is the LV Focus RS 302mm rear rotor and the LS-LV Focus XR5 280mm rear rotor. Note the difference in the height of the hat -



The final negative for the day was simply that I had a new front plastic undertray to fit but it wont fit due to the size of the intercooler I'm using - I'll make an aluminium one instead.

I had an afternoon to spend on the Focus today and finally got a few things off the list.

* 302mm rear brake upgrade is now finally done
* Replaced front oxy sensor
* Fitted longer rear studs
* Fitted replacement steering wheel that I'd had retrimmed over two years ago!
* Fitted replacement shift knob and sift boot - alcantara boot and leather knob with carbon fibre insert
* Finally got my Fifteen52 Tarmac rear wheels on.

Here's the steering wheel -



And finally fitted -