All systems are go for Ford's Focus Cosworth, Auto Express can exclusively reveal with spy shots in its current issue. A secret prototype, testing engine and transmission parts for the forthcoming rally replica, was spotted by our spies as it stopped for fuel in Sweden.

With Focus RS bodywork and huge air scoops, the bright red machine was not hard to miss. However, the test driver was unhappy at being photographed and spun all four of the car's wheels as he raced away from the forecourt.

Destined to be a carbon copy of the company's sensational new World Rally machine (see panel), the Focus is aimed at rivals such as the Mitsubishi Lancer Evo VIII and Subaru Impreza WRX. While it's not expected until at least 2006, current plans will see the performance model launched soon after the next Focus, due in showrooms in 2005.

Set to offer at least 300bhp, the Cosworth has a four-cylinder turbocharged engine, as on the WRC version. Based on the new Focus platform, it will be slightly bigger than the current flagship, the acclaimed RS. A close-ratio six-speed gearbox will give the Cossie supercar performance, with 0-60mph dispatched in six seconds and a 155mph top speed.

Lightweight materials such as aluminium and carbon fibre are used to further boost performance, while inside, luxury is abandoned in favour of functionality. As well as bucket seats and a carefully designed dash, drivers will be offered a starter button and clearly labelled instruments, including turbo boost and temperature gauges similar to those seen in the last Escort Cosworth.

Traction control and ABS will be crucial to the behind-the-wheel experience, although insiders say these aids will be developed purely to enhance involvement, rather than reduce the driver's influence. Such set-ups are already seen on the Evo VIII, which counters speed-sapping understeer and oversteer with automatic yet subtle use of the brakes.

Demand for the Cosworth is likely to be high, particularly given the success of the RS. Ford is considering turning it into a serious production machine.

Only 7,000 Escort Cossies were built between 1992 and 1996, and while exact figures have yet to be finalised, the new machine would aim to double that figure. Higher production numbers will also mean lower prices. Nothing is set in stone, but the model is likely to cost around £28,000 - more expensive than the Subaru and Mitsubishi, but cheaper than performance cars such as BMW's M3 and the Mercedes C32 AMG.

Dan Strong