How to Build a Rally Car : M-Sport Poland’s NEW Ford Fiesta Rally3 Rally Car for Junior WRC 2022

How do you build a rally car? Seb Scott looks at M-Sport Poland’s NEW Ford Fiesta Rally3 rally car, to be used on the Junior WRC 2022 Championship and available to other M-Sport rally customers. See how to build a rally car ; the rally car bodyshell preperation, rally dampers, engine, wiring loom, parts and livery. a lot of work by M-Sport Poland to build a Ford Fiesta Rally3 rally car, ready for the Junior WRC 2022 with 4 wheel drive, 215bhp and 400Nm of torque.
Want to drive in the Junior WRC? Find out more here : www.wrc.com/en/news/2021/juni...
Full M-Sport Ford Fiesta Rally3 Specification and Sales Info here:
www.m-sport.co.uk/fiesta-rally3
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The WRC is the FIA World Rally Championship, a tough motorsport using rally cars on real roads around the world. Watch the best rally drivers battle on gravel and asphalt roads with mud, rain, dust, ice and heat!
Each rally has timed sections called special stages, on closed roads. Drivers complete these stages as quickly as possible. A co-driver reads pace notes that explain the hazards ahead. Rally drivers use the same rally car to travel to each stage on public roads, following normal traffic regulations. The crew which completes all the stages in the shortest time is the rally winner. Championship points are won using the same scoring system as Formula 1. The championship is administered by Fédération Internationale de l'Automobile (FIA), motorsport's world governing body.
Over 30 countries have hosted WRC rallies. Rally Monte Carlo, Rally Argentina, Rally Finland, Rally Portugal, Tour de Corse on Corsica, France, Rally Sardegna on Sardinia, Italy, Safari Rally in Kenya, Acropolis Rally in Greece, Rally New Zealand, Rally Australia, Rally Japan, Rally GB, Rally Catalunya, Rallye Deutschland, Rally Mexico and many more.
Some of the world's greatest drivers have won the FIA World Rally Championship for Drivers, like Colin McRae, Carlos Sainz, Walter Röhrl, Stig Blomqvist, Petter Solberg, Ott Tänak. The list of world rally champions includes many Finnish rally drivers like Juha Kankkunen, Tommi Mäkinen, Ari Vatanen, Marcus Grönholm, Hannu Mikkola. French drivers have had success with Sébastien Ogier, and 9 times world champion Sébastien Loeb. Famous drivers from other motorsports have come to try rally driving like Ken Block from Rallycross, and Robert Kubica and Kimi Räikkönen from F1.
Car companies compete for the prestigious FIA World Rally Championship for Manufacturers awarded to the most successful WRC constructor. Winners include Citroen, Hyundai, Volkswagen and Peugeot. Ford have had success with the Ford Escort, Ford Focus and Ford Fiesta when the M-Sport team won in 2017.
The 1980's featured the iconic Group B rally cars like the Lancia 037 and Delta S4, Peugeot 205 T16, MG Metro 6R4, Ford RS200 and Audi Quattro.
Japan dominated the 1990s with the Mitsubishi Lancer, Subaru Impreza, and Toyota Celica and Toyota Corolla. Toyota returned to the WRC in 2017 with the Toyota Yaris WRC, winning in 2018. Hyundai won in 2019 and 2020 with the Hyundai i20 Coupe WRC. Find out about the latest winners and champions at www.wrc.com
0:00 Intro at at M-Sport Poland
2:24 Bodyshop at M-Sport Poland
4:07 Paint Shop at M-Sport Poland
4:24 Quality Control at M-Sport Poland
6:26 Dampers at M-Sport Poland
9:44 Engine at M-Sport Poland
11:39 Electrical at M-Sport Poland
13:33 Car Build at M-Sport Poland
14:32 Parts at M-Sport Poland
17:17 Geometry and Livery at M-Sport Poland
17:42 Shakedown Test at M-Sport Poland
#GoFurther #Ford

[@johnshaft5613]

I love this sort of thing. What surprises me the most is that there is a market for so many Fiesta rally cars. That facility is basically a production line.

[@user-hk3vu4mh4q]

what is you name

[@tarabottogino]

@@user-hk3vu4mh4q John.

[@user-hk3vu4mh4q]

@@tarabottogino 👍

[@nolimitdriving8252]

I think Rally cars need to be replaced ofte because of the hard conditions and wear it faces during it's lifetime.

[@paweltodudek]

You need to remember that these guys are Polish and the have learnt English as well as mechanical engeneering

[@MrHansBattle]

Impressive for Poland to see Ford sourcing this motorsports initiative end-to-end from the country. Only a handful of years ago this would have likely been in the UK. Hope to see more of such development programs in Poland in the future.

[@nameinvalid69]

The stripe down neat lay out on the ground is... INSANE 😱

[@woocash6537]

Czapki z głów! Kuba libre! Hats off for all polish engineers working on groundbreaking things and processes!

[@thetechfromheaven]

This is simply amazing, the combination of science, experience and ingenuity to build art from ground up. I admire the skills of all these people!

[@niklasmonthan]

Now i can start building 😆

[@zepter00]

Poland land of skilled amd educated enginers 🙂💪🏻🇵🇱

[@TheEryk03]

I land pełen socjalistycznych polityków którzy skutecznie utrudniają pracę tym wyedukowanym inżynierom :) No ale po__laczki sami sobie och wybierają.

[@mrghostly1118]

@@TheEryk03 I brak psyholgicznych dostenp dla ludzi co powinni co najmiej 4 razy w roku sprawdzic siebie. To bym im pomoglo, nawet mi :I

[@TheEryk03]

@@mrghostly1118 ale w czym problem? Po prostu idź do psychologa.

[@vihreelinja4743]

ahahahahahahah

[@nolimitdriving8252]

I love how much work they put into it to make it just perfect for rally driving.

[@chrisallan4591]

The automotive industry accounts for over 11% of Poland's economy... along with exemplary technical expertise and craftsmanship necessary to produce such cutting-edge competition machines, it's no surprise that these cars are built there.

[@roadisland8199]

Great vid! I love the tube and cage work. Especially the subframes which look super light.

[@heebahobba5838]

First ten seconds and I’m super amped. And I’d like to thank you for taking the time and creative capacity to produce this video!

[@markycupko]

Amazing video, cant wait to see them in action this year!

[@oliveringram3056]

And the main contributor, Malcolm Wilson. The young lad I used to watch rallying back in the 70's. Thank you Malcolm, hope your success continues. [Going to have to stop eating all those pies Seb before becoming a co-driver...!!]🤣🤣

[@PerplexedPhoton]

That roll cage fab was sweet!

[@arminkierylak9620]

Tak trzymać, Panie i Panowie. Made in Poland.

[@GTLB302]

They need to build a road legal one, competitor to the gr yaris. A proper fast ford!

[@Dfpijgyt564s65sgt]

They’re all road legal already as they race on public roads.

[@gwot]

@@Dfpijgyt564s65sgt I'm assuming "they" as in Ford, "build" as in production model you can buy off the dealership. Like you can do with the GR Yaris

[@LS1conehead]

@@gwot YES, THIS! But at the very least, Malcolm & Co. should make the whole drivetrain, subframe assemblies, and the suspension available all by themselves for all of the street Fiesta owners out there who want to convert to AWD.

[@gwot]

@@LS1conehead HA! that whole kit probably costs 2 fiestas

[@jesperbrudigam9886]

nope they are not, they used different number plates during rally, cause its not road legal cars.....@@Dfpijgyt564s65sgt

[@streetkingfrankenstein2809]

Im going to be building my own rally car with a 4G63T that I have and going to swap it in a 93-96 Toyota Celica. Its going to be exciting and this video really helped and inspired me so much more!

[@FrankOlsonTwins]

I've driven a Fiesta or two in my time, but this is one Ford Fiesta I'd actually love to own!

[@LS1conehead]

Except for the sequential Sadev box, and 'on/off switch' (AP Racing??) clutch (for launching/starting out only), this is the most 'street-able' of any AWD Fiesta rally machines. 😉👍

[@autofrost3255]

Great video just wished they got into more details with the individual systems

[@alijack6444]

Love the sound of the 3 cyl, sounds like a high revving straight 6

[@Milen4u]

Great to see this happening in Poland! When was M-Sport Poland established?

[@saiko953]

I'm polish and I've never knew that there's a WRC car factory in Poland.

[@mrghostly1118]

yeah, i mean games and internet and all other media of more * in attention* countries steal our attention of our oprtunities, possibilities and awareness of our surroundings.

[@sebastiangebal9662]

Bo to nie WRC tylko auta nowej kategorii Rally3. Auta WRC ( obecnie Rally1),oraz R5 (obecnie Rally2) produkowane są w macierzystej siedzibie M-Sportu, w UK, nie w M-Sport Poland.

[@saiko953]

@@sebastiangebal9662 Zdaje mi się że to są auta Junior WRC czyli mają przynależności do WRC

[@tomtd]

I’m British and always thought M Sport was in the English north west.

[@petergordon4525]

@@tomtd it is, Cockermouth in Cumbria!

[@vihreelinja4743]

Cool to see a Kemppi welder outside of Finland :D That is a well build machine and i have a similar model myself

[@pip5461]

Excellent work, and was received just in time...!

[@l.k.l1971]

Marcus Grunholm my all time favorite rally driver!!!!! Long time dream to drive a rally car!!!!

[@R3FL3X84]

its basically like a fiesta R2 but 4 wheel drive and few more horses, great car :)

[@ajwright5512]

MSport's videos are excellent.

[@michaeldunn6954]

Did he really say "its these three holes we are getting all the power from" 😄

[@binbin7756]

Niesamowite. Szczena opada

[@elevatorvideos2610]

i love wrc 💪👏 happ new year wrc and wrc 2 and 3 and wrc juniors

[@michaelshepherd7572]

Great host, he looks like a heavy Freddie Mercury. Very cool inside look into the build.

[@TheGentlemensMotorRacingTeam]

What a fantastic and inspirational video.

[@czystadusza3365]

Good heavens! it popped up in my yt feed ❤😍🥰🤩

[@MIK33EY]

I’ve recently been consuming all the old rally vids on the VHS Rallies channel, and quite a few have footage of Malcom Wilson actually competing. I wonder what he’d have thought if you were to tell him in the late 70’s or early 80’s that in 2021 (and earlier in the 2000’s) he’d own and run M-Sport, be racing in GT3 with Bentley, be building WRC Fords in Wales and be building a new Rally3 Ford in his new Factory located in Poland? 🤯🤯🤯🤯🤯

[@sergialadid]

Sadly the Bentley GT3 program has ended but yeah it's kinda crazy

[@palmeraz73]

Great Effort. It would be cool if the content was in more detail.

[@TARTANATORscotland]

Amazing workshop

[@chopperhehehe]

Cool build would love to see more 👍👍👍😜🏴󠁧󠁢󠁳󠁣󠁴󠁿🦕🦄😁🤞✌

[@_Moki__]

As a Pole. I'm very but a VERY proud that such a things happening in Poland. My dream is to work there

[@zakariazaki7513]

I like this video keep going 🤠 greeting from Morocco

[@derekw7848]

Good video! Get that guy on a treadmill!

[@saddammalima8458]

Just need more on rally spec engines though

[@Sir_morv]

Really awesome video!!

[@AXXeYY]

impressiv that even Rally3 cars is AWD now days! that i like alot

[@TheJomper1]

Sounds Awesome!

[@daveytn]

Id liked to have seen a lot more details about this

[@froggysandwich1373]

Cool ! Now I came build my own 😁

[@suchasreallife]

Would love a more in-depth version of this a more breakdown of the parts used materials and specs

[@user-nm6sp1eg5o]

Lol. Buy one and you van check IT itself. No one will tell you that because company spend milions to develop car and don't want someone used and proffited from their work without paying.

[@j4v-cyberpunk-music]

I am sure I am not the only one that is into Rally and Rally Cars, but actually in those second hand build ups that have a proper street legal number plate. For some old models there are fibre glass body kits out and some Rally able spare parts are actually cheaper than OEM once, like those Bilstein gas suspension. The reason is that Rally style driving can be done without breaking the traffic laws, because the interesting roads are those winded, narrow once that have no special speed limit for a reason.... My whole point is that it is still difficult to get performance parts to upgrade especially stopping power or overall safety from belts to cages that can be turned street legal, even so those parts would increase overal car safety. I would like to have 600hp, or just another 100 on top of my stock 130 from my 4cyl, but more grip and cage would be first, because I am a rally guy no GT Autobahn pedal to the medal freak and car posing is for luxurious rides that won't get dirty and have no ground clearance...

[@MattinhoGG]

Nice to Paul Blart taking an interest in motorsport 👍😂

[@poppops62]

Great video. 👍

[@a-fl-man640]

you guys need some car rotators, makes doing fabrication/welding/etc so much easier. i built a set in the 70s and still have them.

[@spider19728]

I wonder how much one of these incredible machines would set me back!!

[@matijavicar9519]

100 000 eur

[@Procustom_pl]

Big Team , Grats!

[@dtrain-uwu]

The Fiesta rally cars look so good. I'd buy one just to drive to McDonalds. Great video but the microphones were a bit quiet

[@mahasat]

buy Fiesta ST is pretty much a rally car for streets, i recomand it you wont leave McDonalds parking

[@LS1conehead]

@@mahasat As an owner of one, I wholeheartedly agree with this. ❤👍👍👍👍

[@osianmeilyr89]

Listening to all the different accents is interesting

[@vlissblisskiss]

would love to convert my FiST to something like this!!

[@id104335409]

So clean!😮 If I eat off the floor I would be the dirtiest thing there!

[@ranjitsian5481]

Good work 👍

[@user-ys2dt6dn1i]

THE PROFESSIONALES!

[@johnelway4826]

Nice weather for rally? Poland: yes

[@Rogerjatsu]

This is awesome😊

[@io4k967]

Wrc3 future top class!

[@wojciechkokoszka8249]

bardzo dobrzy aktorzy

[@albertcars4001]

Lovely job!!!

[@mexid2569]

I wanna work here as a mechanic. Make it happen universe!!!

[@ananthkumar-do4tm]

Well done 🎉

[@luisquinones6998]

Excellent! Wow!!!

[@Alekoubas]

Great video, and hats off to all the skilled people invloved in this. However, what is shown in this video is not "development" and the word was seriously abused. This was production/assembly. It would have been nice to see some engineers testing some prototype parts, or some designers working their magic over CAD stations. That is what I would call development, not the process of a welding the roll cage in a car on the production line. My question here is, does anyone know if the whole R3 spec specific parts for the MK8 Fiesta were developed in Poland, or some in UK too? It is only clear about the wiring harness from the video. Also, have they been involved in the development of any other cars, or is this the first? It is super interesting to see the expertise and hard work of these people!

[@GoodolOzzy]

I really enjoy the behind the scenes action of what goes into these cars. Also, much to my relief, I witnessed no fist/elbow bumping and mask wearing cringe throughout this video. A solid handshake at the beginning. Hallelujah!

[@perenevoldsen1054]

Fed video

[@iamarobotninja]

Great guy 👍

[@bartolomejcir9338]

I love Ford

[@tomhamilton9140]

From Texas USA Go Ford.

[@outbox8492]

my dream garage, 25 wrc fiesta white

[@RichardHennigan]

This car is so much fun to drive in RBR.

[@DarkIzo]

they have r3 fiestas in rbr ? time to reinstall that game

[@lux-polprzedsiebiorstwopro2997]

Wooow szok

[@CrazyLeoNet]

Thanks for sharing. What about break-in?

[@ShalomBrother]

I always wondered what Tosh was upto after he finished on The Bill

[@ganiqwest]

M-Sport FANTASTIC operation. Quality Job from start to finish. Where / How does a crazy American buy one? Cost? Realisticaly, to properly run a Rally car what else is needed? I would suspect if I wanted to jump into this fun I need really 2 cars, 1 assembled and a second on the sidelines in parts. Would it be safe to assume that a 3rd (in parts) is being refurbished once the season is underway? An amazing enterprise.

[@LS1conehead]

(Barry) McKenna Motorsports was the sole U.S. distributor for M-Sport machinery in recent years past, but not sure that he is still here in the country now, or repping Malcolm's products anymore. ??? I also believe that for anything under the R5/RALLY 1 WRC level, one may HAVE TO buy their cars/parts/kits DIRECTLY from M-Sport Poland. (??)

[@despizedicon]

It'd be interesting to see a monetary figure going as the car goes together.

[@LS430VIP]

Bit late to this reply, but for anyone wondering, the price cap for Rally3 was 100,000 euro ex VAT, I think M-Sport were offering these for 99,999. It's risen a little since due to inflation, but the price is still capped by WRC to keep it affordable for new drivers. Rally4 and Rally5 are priced lower and so on.

[@kubbo5953]

thx, got lost in the paper instructions, video is more usefull

[@robertrishel3685]

I’d rather have one of these cars over ANY current super car or sports car for sale…Without question! It would be the ultimate weekend driver, in full gravel spec. I would never want or need anything else.

[@LS1conehead]

I feel that same way about the R5/Rally 1 Fiestas. 😉👍 But I would want it in 'rough tarmac' spec (like they are set up for Rally Germany, or some of the bumpier Euro/National tarmac rallies).

[@ramadhanisme7]

Nice one

[@tobymcnicol922]

Impressive. How many chassis will get built? What does a finished car cost the customer?

[@lskovly]

Price about 100.000 euros.

[@tobymcnicol922]

@@lskovly that would be pretty reasonable considering the the amount of work that goes into them

[@LS1conehead]

@@tobymcnicol922 As well as the close to 500,000 Euros for a NEW R5 class ride.

[@vihreelinja4743]

Wow i would not have imagined that they use mcpherson type of suspension in rally. it seems so fragile and the turning radius is not really symmetrical.

[@BeAPickle]

This single junior's sport inventory costs more than my entire freaking life :(

[@Okipouros]

I was about to say Malcom Wilson should get atleast and OBE, but he already has

[@chandrachurniyogi8394]

have been looking to acquire a fleet of five rally prepared brand new Ford FIESTA RS WRC 4TRAC® 4WD + 1.5 in. Lift 1.8 i-Turbo I4 5-Dr Rallye Hatchback (RHD) . . . advise on contacting M-Sport . . .

[@nelpheng8881]

I really love rally car . And I really want to have a car to drive and training in Cambodia. But sadness that I don't have money for this. But my It's my dream.

[@ayoubsayhi3485]

amazing, what can i do to get a job at M-Sport as a mechanical engineer ?

[@ShadowOps15]

Apply ofcourse

[@zepter00]

And learn Polish language 😆

[@LS1conehead]

Does anyone know the bolt pattern/PCD used on this car?? Is it the same as the latest gen Focus, Focus ST/RS (5x108)???

[@michaelmanese2228]

Watching at 2022 😎🇵🇭

[@Happymali10]

So...rally 1/WRC is a silhouette car, but Rally 3 is still based around a production chassis?

[@Countrymusicnumber1]

cant wait to see the new cars drive down gravel roads

[@jonathanyanes602]

Hello I am crazy maniac looking for build a fun rally car. Can I get some help please. On what things I need to change

[@immarcos007]

I liked it, where can I leave my resume?

[@brianb-p6586]

Interesting video, but the audio level is far too low.

[@SKAVSTADEATHCREW]

I want one how much is it

[@einoware436]

Doesn't this increase the costs of running jr. wrc by quite a lot ?

[@LS1conehead]

You have to define "quite a lot". Yes, of course they will initially be, and long term upkeep/'consumables' be higher cost than the current R2/R2C rides, but MUCH MUCH lower co$t overall than the R5 cars. That's the whole idea behind them, as an AWD platform 'stepping stone' to the R5 cars. 😉

[@PaladinofRealm]

hey so uhm..where can i buy one?