How to Make a Rally Car


In today’s ultra competitive motor sports arena, you are sure to find a track you will like if you participate in a rally car race. This form of racing involves a type of vehicle that can go from dirt roads, to river crossings, to high-speed paved road races, making it the most diverse form of motor sports available today. The perfect rally car is small, lightweight, and able to handle the quick turns and road conditions. Here’s how to make a rally car.

Things You'll Need

  • Chassis
  • Roll cage
  • Engine components
  • Wheels
  • Tires
  • Hand tools
  • Welder
  • You can make a great rally car from quite a few selections of manufacturer’s street model vehicles like the Ford Focus, VW Jetta, Honda Civic and other body frame styles that can handle, sharp turns and still go fast. This type of vehicle makes the best rally car.

  • Because rally road races are performed at extreme speeds and in difficult driving conditions, a roll cage is a must in the event of accidents, roll-overs or collisions with obstacles you may find in your path to a win. Have a roll cage installed so that you have the protection you need in the event of an accident.

  • Though you can take a stock Ford Focus to a rally race, you will surely not win without boosting the performance of your stock engine. Air intakes, brakes, computer controlled fuel systems and performance exhausts all add to your rally car's performance. Be sure you take the time to build more horsepower with improved engine components.

  • Because your new rally car will be expected to traverse a multitude of different road conditions, you will need a set of tires and wheels that work well under the expected conditions. By fitting your new rally race car with quality wheels and tires you will increase you chances of winning it all, or losing control if you don’t include this important piece of rally car equipment.

  • Every winning race car has been tested and tuned prior to performing at its best levels. Now that you learned how to build a rally car you are ready to be safe while you compete for rally race trophies, and prize money. Be sure to test your new rally car for as many quality checks as you have added to the original chassis and engine. Welds, connections, nuts, bolts, gaskets, o-rings and dip sticks need to be check for their performance when able. Now that you have done all the work, get ready to enjoy the new experience of running in a rally car race.

Tips & Warnings

  • During the process of upgrading a stock chassis and engine to have the ability to compete in this very demanding sport, you will find that each new step you accomplish in this process leads you to the next. Be sure to involve people who know what makes a rally car perform well while keeping safety the top priority. Remember a rally car race can be dangerous if not performed properly with adequate equipment needed to truly succeed.
  • Welding is needed for the installation of a roll cage. Though you can find roll cages that can be bolted to a chassis, you should consider having the cage welded to insure the strength and capability of its safety.
  • Finding a good price is easy with all the online dealers of engine parts and performance improving components. Unless you are willing to become an expert in all that is needed to learn how to build a rally car, remember that you can find great help from your local race shop or online parts store. Use their experience to help you win after learning how to make a rally car.
  • As with all motor sports, racing a vehicle in a rally car race is dangerous, and can result in injury or death in the event of an accident. Be safe. Drive safe.

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