Can a lazy, comfortable, motorway-cruising Ford Mondeo Mk4 really be modified into something that’s capable of keeping up with the best on them on track? Yes, it can. And we did it…
Twelve months ago, we had a crazy idea to buy a bog-standard Mondeo Titanium X and see if we could turn it into a race car. Ambitious? Perhaps. But not impossible. And our ‘Rep to Race Car’ project was born at the start of 2022.
Fair enough, calling our Mondeo a ‘race’ car is a bit tongue-in-cheek. However, calling the project ‘comfortable motorway cruiser to occasional track toy’ didn’t have quite the same ring to it. And we’ll be the first to admit it’s still a long way from a competitive race car. But, as a recent (and very wet!) track day at Thruxton proved, our Mondeo can now hold its own on track thanks to some sensibly placed upgrades.
But why start with a Ford Mondeo? Good question. The answer is quite simple. It’s not been done many times before and it would have a greater visual impact than starting with a sporty model like an ST or RS. Plus, if you choose the right model to start with, the Mk4 Mondeo offers some decent tuning potential to tap into.
The model we went looking for was the Titanium X, with the same fabled 2.5-litre Volvo-derived five-cylinder Duratec engine as found in the Mk2 Focus ST. In the Mondeo, power is toned down to just over 200bhp, but there’s scope to unlock a lot more. That’s exactly what we intended to do.
But before we could do anything, we needed some tools for the job. When we spoke to Teng Tools UK about the project, they were so keen to make the transformation from rep-mobile to race car happen that they asked if they could be the headline sponsor for the whole project. Of course, they send out a selection of the finest hand tools for us to use when installing the upgrades too.
Next up, we mentioned the project plans to friend of the mag Mark Sargeant at Ford Parts R Us and he was quick to get on board too, offering to store the car and use his workshop as a base for the build. That’s of the beauty of the modified Ford scene; everyone is there to help one another out, and one person’s crazy vision suddenly becomes a team effort and one step closer to reality.
The same is true for parts suppliers and manufacturers too. After sitting down with Mark and working out a precise build sheet and listing all the performance upgrades we were going to need if we’d have any hope of making our Mondeo go around a racetrack, we started making calls and sending emails to specialists all over the world.
As you can see from the logos splashed all over the car, we got a fantastic response with everyone wanting to help. The fact the car will be raffled off and the funds donated to charity later this year means not only do their efforts assist us in having some fun during the build, but they’ll be making a serious contribution to a worthy cause too.
Modified Ford Mondeo Mk4 exhaust changes
Those of you who have been following the build will have seen that the first upgrades were a Scorpion exhaust and new alloy wheels and tyres. Despite having a meaty 2.5-litre under the bonnet, you could barely hear the engine running at all. Where was that famous five-pot rumble? It soon appeared after we’d installed a full turbo-back system, including sports cat. Now it even has authentic pops and crackles on the overrun too. Nice.
Chassis modifications for the Ford Mondeo Mk4
Wheels and tyres were next. We opted for Rotiform’s BUC-M design because it has a nice multispoke style that looks a bit like a BTCC wheel. Plus, we know they’re quality and can cope with harsh road conditions like potholes and speed bumps too. They’re fitted with Toyo R888R tyres; why would you fit anything else to a track car?
Sorting the suspension out is a set of fully adjustable coilovers from PB Coilovers. These units offer plenty of ride height and damping adjustment and allowed us to dial in the settings to get everything just how we wanted. The balance is now perfect for both road and track use, although as we get faster on track, we may even look to firm things up a little further.
Aiding the handling, we removed a substantial amount of weight from the interior. The stock half-leather, heated seats were very comfy but not very supportive. And incredibly weighty. Replacing them with a pair of lightweight reclining bucket seats from Corbeau allowed for comfort for road use and supportive for track work. It also allowed us to fit some proper Luke four-point harnesses for the track while retaining the OE belts for road use.
The modified Ford Mondeo Mk4 paid EBC a visit at their Northampton-based HQ. The R&D team set about designing a kit that would see EBC’s famed Apollo four-pot calliper and 355x32mm fully floating discs fitted to the front. A set of matching grooved rear discs were also added, and Bluestuff pads fitted all round.
Under the bonnet, that famous five-pot breathes much better thanks to a Ramair induction kit. The air filter alone made significant improvements. However, we didn’t stop there and decided to install a big-bore crossover pipe too. Intended for the Focus ST, this meant a bit of tweaking to the Mondeo’s vacuum pipes. This basically meant converting it to the same setup on the Mk2 Focus RS. We now enjoy all the extra torque benefits of the higher-flowing pipework too.
Cooling and performance upgrades on the Mk4 Mondeo track car
An Airtec intercooler ensures it all stays cool. Even after an afternoon of action flat-out around Thruxton, the temps remained steady throughout. Not only that, but the improved design also poses less restrictions than the stock intercooler. This helps free up some power and becomes a must-have for any tuned Mk4 Mondeo.
Ensuring it all stays together, the Mondeo took a trip to BD Performance for one of their block mod upgrades. BD always goes the extra mile fir customers, and they certainly did for us. Not only did they install the block mod but they also gave the cylinder head a skim and refresh. On the list of work included fitted a timing cambelt, and gave everything a thorough check over too. They also installed the Helix heavy-duty clutch and single-mass flywheel upgrade we wanted to fit too.
The final stop was Collins Performance in Cheshire. Strapped on the dyno we were pleased and a little surprised to see that the car was making 230bhp just from the hardware upgrades alone. But it would soon be a lot more as Martin Collins got to work writing some custom software specifically for this car.
The result was a very healthy and impressive 282bhp on regular 95RON pump fuel. On V-Power or Momentum, Martin reckons it’ll be making closer to 300bhp.
We could have pushed the limits and smashed through the 300bhp barrier even with the relatively simple bolt-ons we’ve added. But as the car is destined for a combination of flat-out track use and still needs to be dependable to drive to shows and events throughout the summer, we asked Martin to make sure it’s kept well within safe levels for maximum reliability. We’re happy to sacrifice a few bhp for the added peace of mind that it’ll take anything we can throw at it.
Mk4 Mondeo styling upgrades
With all the right bits in all the right places, we then needed our modified Ford Mondeo Mk4 to look like a race car. With Teng Tools on board as the main sponsor, plus support from loads of the biggest names in the aftermarket tuning scene, we spoke to our friends at 3M and got chatting about wrapping the car in a full race-style livery. Helen Stanley was drafted in to draw up an artist’s impression of what the Mondeo could look like, and 3M’s team of graphic designers and vehicle wrappers set about making that vision a reality.
Then came the big test, the track day at Thruxton. The wet conditions weren’t ideal but did give us the perfect opportunity to really see what difference the upgrades have made. The transformation is incredible. The Mondeo didn’t feel out of place at all, which is quite a testament considering the machinery it was sharing the track with. It’s certainly much more ‘race’ car than ‘rep’ mobile these days.
We know it’s not really a competitive racer and has just been a bit of fun to build, but what the project has really shown is that when it comes to tuning Fords you can take something seemingly unsuitable, and with the right upgrades, the right tools, and help from the right specialists, you can turn it into whatever you want. Whether that’s a track toy, a show stunner, or something that you can enjoy every day, you can customise a Blue Oval to be whatever you want it to be. More importantly, you can have huge amounts of fun in the process. And at the end of the day, that’s what it’s all about.
Win this modified Ford Mondeo Mk4 track car!
Want to win this car? Visit here or pop along to one of the Fast Car Entertainment shows this year and you can enter our raffle to win this very car. Tickets cost £5 each, and all funds will be donated to the Children With Cancer UK charity.
Project partners
We want to say a huge thanks to all those companies who supported and assisted with this project.
Teng Tools UK
Ford Parts R Us
07446 487799
Scorpion Red Power
Rotiform
Toyo
3M
Airtec
PB Coilovers
EBC Brakes
Ramair
Corbeau
BD Performance
Helix
Collins Performance
Tech Spec: Modified Ford Mondeo Mk4
Engine:
2522cc five-cylinder Duratec turbo; Ramair foam induction kit; Ramair Focus ST crossover pipe; Ramair ECU holder; Scorpion sports-cat downpipe; Scorpion resonated twin-exit cat-back exhaust; Airtec front-mount intercooler; BD Performance block mod; custom Collins Performance remap.
Power:
282bhp and 332lb.ft (on 95RON fuel)
Transmission:
Mondeo Titanium X six-speed M66 gearbox; Helix heavy-duty organic clutch with single-mass flywheel conversion
Suspension:
PB coilovers all round
Brakes:
Front: EBC Racing Apollo four-pot callipers with 355x322mm discs; Bluestuff pads; and braided brake lines; rear: original callipers with EBC grooves discs; Bluestuff pads; and braided brake lines.
Wheels and Tyres:
19×8.5in Rotiform BUC-M alloys; 5×108; ET45 in gloss black with 235/35/19 Toyo R888R tyres all round
Interior:
Corbeau RS2 reclining bucket seats mounted on Corbeau/Mk4 Mondeo subframes; Luke four-point harnesses; rear seats and carpets removed.
Exterior:
Custom Teng Tools race-inspired wrap by 3M; designed by Helen Stanley.
