Go Back   Team-BHP > Under the Hood > Modifications & Accessories


Reply
 
Thread Tools Search this Thread
Old 7th June 2017, 15:51   #106
BHPian
 
PratikPatel's Avatar
 
Join Date: Sep 2010
Location: Mumbai
Posts: 147
Thanked: 641 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Just wanted to give a heads up to people who have been following this thread. The lack of updates is not for want of work to be done on the car. In fact a lot of the parts have come in and we are ready for the installation.

Unfortunately, I have suffered a bad bike crash which has left me with a broken femur in the left leg, a broken radius in the left hand and multiple breaks in the right hand radius and ulna. I was extremely lucky that I had all my riding gear on or else it could have been even fatal if not life changing injuries.

I am recovering well now. Doctors have said 3 months, but hopefully I should be ok in couple of months. Will start working on the car once again after I been given ok by the doctors.
PratikPatel is offline   (4) Thanks Reply With Quote
Old 7th June 2017, 16:30   #107
BHPian
 
Join Date: May 2016
Location: Pune
Posts: 137
Thanked: 179 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Get well soon Pratik!
varunswnt is offline   Reply With Quote
Old 7th June 2017, 17:00   #108
Senior - BHPian
 
extreme_torque's Avatar
 
Join Date: Feb 2005
Location: Melbourne
Posts: 3,546
Thanked: 1,312 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Quote:
Originally Posted by PratikPatel View Post
Just wanted to give a heads up to people who have been following this thread. The lack of updates is not for want of work to be done on the car. In fact a lot of the parts have come in and we are ready for the installation.

Unfortunately, I have suffered a bad bike crash which has left me with a broken femur in the left leg, a broken radius in the left hand and multiple breaks in the right hand radius and ulna. I was extremely lucky that I had all my riding gear on or else it could have been even fatal if not life changing injuries.

I am recovering well now. Doctors have said 3 months, but hopefully I should be ok in couple of months. Will start working on the car once again after I been given ok by the doctors.
Gosh that sound awful. Get well soon mate. All the best with the recovery.
extreme_torque is offline   Reply With Quote
Old 7th June 2017, 19:16   #109
BHPian
 
Join Date: Jan 2015
Location: Mumbai
Posts: 38
Thanked: 28 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Hi! came across your posts today. Firstly, hope you get well soon. Secondly, read your thread, and my mouth started watering! I own a Fiesta 1.6SXI (2011 model) , but not badged as Classic. I do have ABS and dual Airbags. I have covered just 28,000km till date. (since I use other cars as commuters) and I drive this one only for pleasure.

So with ABS , I am pretty happy with my brakes as they are. Alloys are OEM and I replaced the OEM tyres at just 25,000km since I was a bit worried at slight cracks on the sidewalls. I replaced them with Yokohama Earth1s and these are better then the originals, and use nitrogen only with these tyres.

Your mods are very technical, and time consuming. Living in Mumbai, I will have to find a garage/mechanic who can do something along these lines.

I am tempted to play safe, and just do minor jobs like free flow exhaust, better spark plugs etc, since I am more worried on the long term reliability of highly technical mods. on the car.
But I do hope that the work you are doing on your car will encourage other enthusiasts do some mods on their cars as well.
Incidently my car also has some rust on the window sills.

Would it be possible to share the approx. costs you have incurred so far??
Anyways I will be following your thread regularly from now on.
All the best.
SanjayDalal is offline   (1) Thanks Reply With Quote
Old 8th June 2017, 19:29   #110
Newbie
 
vishal.joshi's Avatar
 
Join Date: Feb 2015
Location: Mumbai
Posts: 15
Thanked: 13 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Quote:
Originally Posted by PratikPatel View Post
Unfortunately, I have suffered a bad bike crash which has left me with a broken femur in the left leg, a broken radius in the left hand and multiple breaks in the right hand radius and ulna. I was extremely lucky that I had all my riding gear on or else it could have been even fatal if not life changing injuries.

I am recovering well now. Doctors have said 3 months, but hopefully I should be ok in couple of months. Will start working on the car once again after I been given ok by the doctors.
Oouch that did hurt. Get well soon mate.

Waiting for the next set of upgrades.
vishal.joshi is offline   Reply With Quote
Old 10th June 2017, 15:27   #111
BHPian
 
antonjeeper's Avatar
 
Join Date: Mar 2013
Location: Cochin
Posts: 31
Thanked: 4 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Very sad to hear about the accident. It was a blessing thing that you had all the riding gear on. Take rest and get well soon Pratik.
antonjeeper is offline   Reply With Quote
Old 28th June 2017, 03:15   #112
BHPian
 
Rohan24's Avatar
 
Join Date: Dec 2015
Location: Bangalore
Posts: 140
Thanked: 123 Times
Default Re: Project ST: Ford Fiesta 1.6 Duratec

Get well soon! Glad that you're okay.
Been following this thread and was eagerly waiting for the next round of mods. Guess we'll have to wait longer, eh.
Ride safe, sir!
Rohan24 is offline   Reply With Quote
Old 3rd November 2017, 16:05   #113
BHPian
 
PratikPatel's Avatar
 
Join Date: Sep 2010
Location: Mumbai
Posts: 147
Thanked: 641 Times
Default Rear Brake Overhaul

Rear Brake Overhaul

It’s been 6 months since my bike crash and I have recovered about 80% with a few complications still remaining. The long road to recovery has not been linear and has its twists and turns, however, that’s a story for another day.

We have finally got down to working on the car to finish up the few pending things before we start Phase 2 of the modifications. Therefore, the next few posts will detail these along with one significant change where we revised a previously done modification to improve performance.

Due to the extent of my injuries my first priority was rehabilitation and therefore the working on the car went to the bottom of the list. Hence, the car was stationary for about 2 months. As the car was stationary it developed a problem. The left rear brake seized up and the car would not move. Just before my bike crash I had discussed with Vikram about overhauling the rear brakes as I could noticeably feel the rear brakes catching when I released the handbrake and put the car into motion.

Vikram was immediately called asked to pickup the car and start working on it. When the rear brakes were opened up we found the brake shoes were almost worn out and there was deep scoring in the drums. The left wheel cylinder assembly was completely seized and the right one was also well along the way to meeting the same fate. Therefore, it was decided that we would replace the complete assemblies.

Vikram procured the drums, wheel cylinder assemblies and break shoes from Ford. The assembly was straightforward without any complications. The wheel cylinder assemblies and brake shoes are of TVS Girling make.

Name:  IMG_0083.jpg
Views: 564
Size:  146.8 KB
Left rear Drum

Name:  IMG_0089.jpg
Views: 561
Size:  95.0 KB
Seized Wheel Cylinder Assembly

Name:  IMG_0091.jpg
Views: 567
Size:  80.4 KB

Name:  IMG_0082.jpg
Views: 560
Size:  84.5 KB
New Brake Shoes & Wheel Cylinder Assembly

Name:  IMG_0084.jpg
Views: 561
Size:  71.5 KB

Name:  IMG_0085.jpg
Views: 564
Size:  58.5 KB
PratikPatel is offline   (6) Thanks Reply With Quote
Old 6th November 2017, 14:35   #114
BHPian
 
PratikPatel's Avatar
 
Join Date: Sep 2010
Location: Mumbai
Posts: 147
Thanked: 641 Times
Default Oil Sludge & Oil Slump Cleaning

Oil Sludge & Oil Slump Cleaning

After 7 years of running and having clocked 50,000 kms, Vikram felt it was time open up the belly pan and clean the same. I was a bit skeptical as the car has always had its regular oil changes, in fact, always about 500 to 1000 kms before the recommended service intervals. While I was very particular about what make and quality of oil that was used in my bikes, I have never really bothered about what oil was put in as long as it was done at regular intervals and done by the Ford service center. Other than that, my wife jealously guarded the car, I was not allowed to even change a nut or bolt that was not OEM. Since the car was for my wife, it was more important that it should be good working condition and should not break down anytime soon. Therefore, I would only get into arguments with her about sending the car for regular servicing (she would resist giving the car up for even a day).

Vikram explained why he felt the need to open up the oil sump. As my wife’s driving pattern and driving habits involved very short trips and frequent stop and go driving, he was of the opinion that no matter how good the oil and how frequent the oil changes were, creation of oil sludge was inevitable.

Oil sludge is created when oil chemically breaks down and collects on engine parts. This usually happens when the oil does not reach optimum operating temperatures and does not circulate enough; both outcomes of very short drives that my wife takes daily. The other reason is that the oil has not been changed frequently enough.

Today’s multi-grade oils are complex chemical concoctions. They contain detergents, anti-oxidants, dispersants, anti-foaming agents and anti-friction agents. Each of these performs a very specific task. For example, dispersant agents grab dust, dirt, debris and suspends them in oil while keeping them away from metal parts to prevent damage to the engine parts. Anti-foaming agents prevent air from working into the oil and weakening its sheer strength and lubricating ability. As engine oil breaks down, it looses these vital additives, which in turn fills the oil up with oxidation materials and contaminants. The continuous cycle of exposure to heat, pressure and elements in the engine stretches the oil’s ability to protect and lubricate. It inevitably leads to point where the oil polymerises into a gel, which either sits in the crankcase or sticks to whichever metal surface it gets carried to.

Extreme or for that matter even ‘reasonable’ amount oil sludge can be dangerous as the same can collect vital areas of the oil circulation system which in turn can lead to reduced oil lubrication and even catastrophic engine failures. Even if it does not, the sludge changes the viscosity of the oil as it a part of oil itself, thereby hampering and reducing the flow and pressure through the entire system.

In addition to lubricating and protecting all the moving parts of the engine, oil has the important function of cooling the engine by removing heat away from vital engine parts. Oil sludge is a good heat insulator, which prevents the oil from removing heat, which in turn puts a lot of stress on the cooling system and engine parts. This has significant impact on engine performance and engine life.

When we opened the oil sump I was a bit surprised to see the amount of sludge buildup. It was a bit of revelation. There was significant sludge build up and it had formed hard varnish like coating in the oil sump. Vikram tried to remove the sludge by using break oil and other solvents. However, it was really stubborn and hard coated. Therefore, it was decided to get the belly pan professionally cleaned through a hot chemical bath treatment.

When we got the belly pan back from the chemical bath it was surgical clean and as good as new. The belly pan was put back on the engine with fresh gasket. Fresh oil was filled into the engine and the engine was warmed up to operating temperatures. We then dumped a can of Wurth Engine Flush and Cleaner in to the engine. The engine was then left to run for 30 minutes. Oil and engine flush were then drained out, a fresh oil filter was fitted and Mobil 1 Racing 0W40 oil was filled in.

Before cleaning of the oil sump, oil pressure was 50 psi, after the cleaning and flushing, it now shows 60 psi.

Name:  IMG_0094.jpg
Views: 399
Size:  94.7 KB
Oil Sludge after 50,000 kms and 7 years.

Name:  IMG_0096.jpg
Views: 395
Size:  68.0 KB

Name:  IMG_0102.jpg
Views: 394
Size:  61.0 KB
Belly Pan after Hot Chemical Bath.

Name:  IMG_0100.jpg
Views: 395
Size:  54.4 KB
PratikPatel is offline   (7) Thanks Reply With Quote
Old 10th November 2017, 16:26   #115
BHPian
 
PratikPatel's Avatar
 
Join Date: Sep 2010
Location: Mumbai
Posts: 147
Thanked: 641 Times
Default Fuel Pressure Meter

Fuel Pressure Meter

In one of our previous post we had detailed the installation of Autometer meters on the car. While the oil pressure gauge and the voltmeter were operational and the fuel pressure gauge was left pending as we ran into couple of issues.

The fuel rail on the Ford Fiesta is a bit of an odd boy. The fuel rail is made up of long fiberglass reinforced plastic. While the adaption of the plastic fuel rails is becoming increasingly common due to the benefits offered, the one of Ford Fiesta throws a few curve balls into equation.

Plastic fuel rails offer the benefits of lower weight and offer better service life through enhanced corrosion/oxidation resistance qualities of plastic. The challenge for many years was creating a injection molded fuel rail which could offer acute angles for the nozzles while mounting on the inlet manifold. Most of these problems have been solved leading to increase adaption of plastic fuel rails.

The Ford Fiesta fuel rail is the design of the fuel rail, which integrates the fuel pressure regulator onto the rail as part of the fuel rail. While many fuel rails do the same, these rails have a screw on fuel pressure regulator, which once removed, the hole can plugged when you want to use an aftermarket adjustable fuel pressure regulator. The problem with Fiesta’s pressure regulator is that removing it creates a big open space on the fuel rail, which is difficult to plug. Hence, the delay in installing the fuel pressure regulator. However, we have over come this and other problems and a post on the installation of pressure regulator will follow shortly.

Before installing the fuel pressure regulator it was imperative to know what is the actual pressure across the rev range. Hence, making the fuel pressure gauge operational was a priority. The problem that we faced was that fuel rail does not have any threading on the inlet side. Ford has made use of Teflon hoses for the fuel line inside the engine bay. Cutting the hose was not an option as without proper cutting tools we could very spoil the hose leading to a very expensive replacement. Therefore, the issue at hand was; how do we mount the pressure transducer?

Vikram fabricated an adapter that would sit between the fuel rail and the hose. The pressure transducer was mounted on top of the adapter. Ultimately, it turned out to be a neat and clean installation.

Name:  IMG_0109.jpg
Views: 255
Size:  56.0 KB

Name:  IMG_0110.jpg
Views: 251
Size:  63.7 KB

Name:  IMG_0111.jpg
Views: 251
Size:  68.7 KB

Name:  IMG_0112.jpg
Views: 253
Size:  54.2 KB
PratikPatel is offline   (2) Thanks Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search


Similar Threads
Thread Thread Starter Forum Replies Last Post
Petrol Siblings: Honda City 1.5 iVtec Vs Ford Fiesta 1.6 Duratec niranjanrvce Test-Drives & Initial Ownership Reports 58 13th January 2015 15:21
Engine block replacement - Ford Fiesta 1.4 Duratec EXI (P) McTurbo Technical Stuff 7 29th August 2013 12:47
Ford Fiesta 1.6 Duratec ZXI, Platinum : Ownership Experience! raamki Test-Drives & Initial Ownership Reports 181 28th August 2011 23:14
My New Sea Grey Ford Fiesta Duratec Sxi Petrol pramodpk Test-Drives & Initial Ownership Reports 9 21st September 2010 10:57
Tested & Ripped:Ford Fiesta 1.6S Duratec...surely FIDA!!!(with alot of detailed pics) katalysm76 Test-Drives & Initial Ownership Reports 56 20th October 2009 23:09


All times are GMT +5.5. The time now is 00:07.

Copyright ©2000 - 2017, Team-BHP.com
Proudly powered by E2E Networks