This is our very own Focus ST MK4 development car. We added it to the fleet a few months ago as we announced on our social media platforms.
Previously owned and with just a few thousand miles on the clock. We couldn’t wait to get stuck in having read lots of good reviews about this platform online by the likes of Evo magazine.
3d scanning
We started with the Focus MK4 ST in the same way we approach all new hardware products. Stripping down the car to see where we can see flaws or areas that can be improved over stock.
Utilising the 3D scanner we are able to scan the OE set up and then remove parts to scan again and see how much we can gain, be this in pipe sizes, core sizes or bend radiuses.
intake options
On the intake side, we were able to see straight away that we would be able to produce a much freer flowing system as there was space available to make much more relaxed bends with larger diameter pipework.
We decided to go with a full refit of the intake all the way to the turbo, this will be made up of both custom-designed silicone hoses utilising stepped end design were required to reduce turbulent flow, mandrel-bent aluminium pipework mated with fabricated brackets for optimum fit.
Finally two options for both an OEM+ style kit retaining the factory airbox with replacement panel filter and a full open cone filter with heatshield. All drawings have been sent out now and will go into the sample stage for test fitting and both flow and dyno testing.
FOCUS ST MK4 intercooler work
The intercooler on the Focus ST MK4 is a very compact unit from the factory, this is mainly because of the way that it has been packaged around the core supports for the radiator and condenser.
With this in mind, we have had to be very clever in the design process to ensure we have a complete factory fit with zero cutting of any of the bumper supports or flaps in the grill.
It was important to us that we retained a full factory fit and finish with the cooler whilst looking at maximising performance where possible. A new design has been done and we have 3D printed and test fitted with success now and moving onto full production samples.
It will consist of cast aluminium end tanks CAD designed using the 3D scanned surroundings to optimise the fitment with our own designed fins in a bar and plate core, custom CNC made brackets and stainless fittings.
By using the scan data we were able to increase the core volume significantly enough without affecting or fouling any other parts. We combined this with new inlet and outlet hoses, increasing the sizes to allow more flow into and out of the larger cooler. Once we have full samples we will be able to capture a plethora of test data with various temperatures, pressure drops and power gains to back up the design to the fullest extent.
FOCUS ST MK4 Brake & Wheel UPGRADES
Using our 6-pot Alcon caliper and 380/355mm discs we have been able to create new brake kits. These are just awaiting samples and then we can test fit and release.
Our current 5×108 Ford fitment RF018/RF019 Wheels fit straight up to the car and can be added to the fitment list.
FOCUS ST MK4 engine mounts
We looked at the engine mounts, in particular, a rear torque mount however the new OE design is such that it’s just not viable to do anything as a full replacement.
We may possibly look at doing an insert into the OE mount to help firm things up but it doesn’t look like it would be a huge benefit at this time. Maybe once the software is installed we can measure to see how engine movement there is once it has more power and re-assess then.
Keep checking back here on the Revo blog for further updates and product releases for this platform.
