Ford set up a secret course in its backyard to fine-tune the new Mustang Mach-E Rally
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To ensure its new Mustang Mach-E Rally car is ready to tackle any terrain, Ford set up a secret course to test it. Ford says its new electric rally car is a testament to what’s possible when you combine passion with design and engineering. Check out how the Mach-E Rally car evolved below.
The electric Mustang rally car is here
“Can we make a rally-inspired version of the Mustang Mach-E?” Ford’s product planners, Peter Schultz and Craig Migliori, were asked in 2022. Their answer? Absolutely.
Shultz and Migliori took a “hand-me-down” Mustang Mach-E GT and added new wheels and off-road tires. After testing it at Ford’s Michigan Proving Grounds, they were confident it could become a reality.
The team lifted the Mach-E GT 1″ with RallyCross-tuned shocks and springs to enable it to tackle rougher terrain. Meanwhile, 19″ wheels wrapped in Michelin CrossClimate 2 rubber and underbody shielding are added to help protect the vehicle.
Not only did the Rally car need off-road capability, but the team also knew it needed a rugged design to accompany it.
Contrasting accents on the upper and lower body moldings, a front splitter and rear spoiler, and a black painted steel roof are added for a more aggressive style. The Mustang Mach-E also features built-in rally-inspired fog lights.
To prove the modifications were worthy, Ford off-road attributes engineer Chris Berchin and vehicle engineering supervisor Jay Kistler put the electric Rally car up to the test.
Ford sets up secret rally course for testing
The team set up a secret 500 combined mile “torture test” course at Ford’s Michigan Proving Grounds. The new course was designed to put the Mustang Mach-E Rally through the equivalent of about ten years of monthly rallycross racing.
Tests included tight turns through loose dirt terrain. “We tested in numerous different weather scenarios and temperatures with conditions ranging from muddy to dry – typical of what rallycross competitors might face,” Berchin explained.
“Likewise, the surface is dirt of varying composition, allowing for different traction scenarios.” Before building the course, the team went to Rallycross events and interviewed drivers to make sure they were projecting a true representation of what the environment looks and feels like.
Using this info, Ford engineers plotted the course with a full computer-aided engineering (CAE) analysis, complete with mapping elevation, exact speeds, timing, and more.
Ford used the tech to make it feel and look like a rally course with data to back it up. The secret in-house course enabled Ford to keep cost and development time down while keeping the electric rally car under wraps.
Ford’s RallySport drive mode unlocks the full potential of the electric Rally car, enabling bigger slides, a more linear throttle response, and aggressive damping for better control.
The Mustang Mach-E Rally has 265 miles EPA estimated range with up to 480 hp and 700 lb-ft of torque. Charging from 10% to 80% is expected in 36.5 minutes. Ford’s new Mustang Mach-E electric Rally car is available for order starting at $59,995.
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