Once the decision to move to FWD had been taken, seven "special order" Mondeo Si bodyshells were built at Ford's Genk plant in Belgium.

These bodyshells were constructed to ARE's specifications which involved deleting all non-essential fixings, brackets and components from their build sheets and taking the cars off the production line prior to being under-sealed and painted.

Once delivered ARE in Coventry, the team set about double spot welding the bare shells and fitted each with a TIG-welded T45 steel tube roll cage. The shells were then painted with only a single primer and top coat, in an attempt to keep their weight down.

The rules stipulate the use of the standard production block and cylinder heads, but Cosworth replaced virtually every other component within the engine with their own custom built items. An all steel crankshaft and connecting rods were topped with aluminum pistons, the engine capacity being reduced down to 2000cc limit by changing the length of the engine stroke.

A purpose built inlet manifold and slide throttle assembly is added to the top of the engine, with Zytek fuel injection and engine management keeping everything in check. Exhaust gasses are fed out to the rear of the car via an elaborate ARE designed and built exhaust system.