The Making of the Ford Mustang Mach-E Rally

A Ford Mustang Mach-E doing early testing on a rally course for the Mach-E Rally.

The Mustang Mach-E® Rally epitomizes the fusion of passion, design, and engineering, transforming a mere concept discussed in an engineering breakroom into a high-performance, rally-inspired reality. This innovative journey reveals the depths of dedication and creativity at Ford, culminating in a vehicle designed for both the rally track and everyday roads. 

Concept to Reality: The Genesis of the Mustang Mach-E Rally

The journey began with a simple yet intriguing question among Ford’s product planners, Peter Schultz and Craig Migliori: “Can we make a rally-inspired version of the Mustang Mach-E?” With a used Mach-E GT, some new wheels, and off-road tires, the team set off to Ford’s Michigan Proving Grounds to test its potential. The result was a resounding affirmation, laying the groundwork for what would become the Mustang Mach-E Rally. 

Ford engineers around a Mustang Mach-E doing early tests for the Mach-E Rally.

Design and Engineering: Building the Mustang Mach-E Rally

Ford’s engineers embarked on a mission to imbue the Mach-E Rally with not only the aesthetic but the capabilities of a true rallycross contender. This involved elevating the suspension, integrating RallyCross-tuned shocks, and wrapping 19-inch wheels in robust Michelin® CrossClimate2 tires. Aesthetic enhancements included aggressive body moldings, a sporty front splitter, and rally-inspired fog lights, all complemented by a sleek black steel roof. 

A professional driver doing early testing for the Mustang Mach-E Rally.

Testing and Validation: Ensuring Rally-Ready Performance

The real challenge was proving the Mach-E Rally’s capabilities. Ford’s off-road attributes engineer, Chris Berchin, alongside vehicle engineering supervisor, Jay Kistler, led rigorous drive tests. These included a grueling 500-mile torture test designed to simulate a decade of rallycross racing. The vehicle was pushed to its limits across a variety of weather conditions and dirt tracks, ensuring its performance met the high standards required for rallycross. 

A Mustang Mach-E doing early testing on a rally course for the Mach-E Rally.

Course Development: Simulating Real-World Rallycross Conditions

Ford didn’t stop at vehicle development. The team also constructed a state-of-the-art rallycross course at the Michigan Proving Grounds. This involved meticulous planning and CAE analysis to accurately replicate real rallycross race conditions, complete with measured elevations and expected speeds. The course was designed not only to test the Mach-E Rally but to stand as a benchmark for rallycross courses globally. 

Achievements and Future Outlook

The Mustang Mach-E Rally project not only met its ambitious goals but was also recognized internally at Ford with a Vehicle Engineering Validation award. This project exemplifies Ford’s commitment to innovation and excellence, with the Mach-E Rally set to hit both the market and the dirt tracks soon, promising an exhilarating blend of on-road efficiency and off-road prowess. 

The new Ford Mustang Mach-E Rally in a beautiful, wooded setting.

From a curious inquiry to a full-fledged rally performance vehicle, the Mustang Mach-E Rally demonstrates Ford’s unique blend of visionary thinking and engineering excellence. As this vehicle prepares to make its mark on both the industry and the rally tracks, it stands as a testament to what can be achieved when innovative minds work relentlessly towards transforming a bold vision into reality. 



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