Vehicle Repairs in the Sahara: A Case Study

16th May 2025

In April 2025, the Max Adventure team set out on an 11 day reconnaissance mission through the Moroccan Sahara. Their goal was to test the route, equipment, and logistics ahead of the Driven to Extremes SAHARA 2025 expedition, which will see members of the public take on a Dakar inspired journey later this year.

The vehicles chosen for this challenge weren’t high end 4x4s or specialist desert machines. Instead, staying true to Max Adventure’s philosophy, the team selected two second hand Ford Focus Mk2 hatchbacks, bought for just £400 and £200. Purposefully chosen to demonstrate what everyday vehicles with the right planning and field ready repair solutions, could take on some of the world’s most extreme terrain.

The route took them across thousands of miles, starting in the UK and crossing into North Africa. From there, they headed deep into the Sahara via the High and Mid Atlas mountain ranges, passed through the striking rock formation of Siroko-Mora, often referred to as the “Dinosaur’s Footprint” and crossed the iconic dunes of Erg Chebbi. They followed sections of the original Dakar Rally route, traversing dried lakebeds, remote desert tracks, and soft sand dunes rarely seen by ordinary vehicles.

Field repairs were inevitable. After a rock strike damaged a gearbox mount, a temporary roadside fix using ratchet straps kept the car moving. But another challenge came after a night of heavy rain, when one of the vehicles failed to start. The issue was traced to air in the fuel system caused by a leak in a plastic fuel return manifold.

To keep the car running, the team applied Resimac’s 109 Self-Amalgamating Repair Tape, providing a temporary seal that allowed them to reach a safer location. A permanent fix followed, using 301 Epoxy Resin & Hardener to re-bond a loose blank fitting. The repair held for the remainder of the expedition, through extreme engine bay conditions and thousands of desert miles.

Resimac 103 Metal Repair Paste and 109 Self-Amalgamating Tape were among the materials taken on the trip, versatile products ideal for desert vehicle repairs and remote application where workshop conditions aren’t available. The epoxy based 103 offers strong adhesion and durability in the field, while the 109 tape provides a fast, flexible sealing option, both proving valuable additions to the team’s repair kit.

Resimac wasn’t the only support on hand, but the products played a valuable role in keeping the vehicles moving. The Max Adventure team acknowledged Resimac alongside other contributors providing tracking, communications, and logistical support.

Following the success of the reconnaissance, entries are now open for the full Driven to Extremes SAHARA 2025 expedition, taking place in September. Participants will take on remote terrain including the vast dried lakebed of Iriki, the iconic Gara Medouar fortress seen in Spectre, and the towering dunes of Erg Chebbi, all in front wheel drive hatchbacks, supported by a professional expedition team.

📷 Images from the expedition can be seen below.

If you’d like to take part or find out more, please visit:
www.driventoextremes.co.uk