[mayankk]

ok.
so the earlier setup was creating a lot of problems,even if it provided the shortest route for the air.
1. Filter constantly nestled against the ECM.
2. Kept getting detached at the throttle body(i think).

got myself a about 2-3 feet of ABS tubing,2" dia.
heat bent it to get a slight curve going, and wrapped in aluminium foil tape.
the highly acute bend in the pic is not really acute, but 90 degs.
yes it disrupts airflow, but you will see method in the madness soon.
flexible rubber sections of about 4" length each keep the hoses attached to each other and the filter.
the roar has gone down drastically.
filter hangs free now, not touching anything.
the support for the filter is attached the original bolt spots for the airbox.
as for the airbox, well it exists within the bay, as you can see.
what you see is the original airbox cut up to donate its top-layer, the one that says "ford" etc..
this is for heatshielding and for aesthetic purposes.


Sorry about the pic quality,just.
Madness is done, now the method.

See,this has turned out to be more of a headache than i thought possible.
either my filter is too big,or ford seriously do not want nybody doing some sort of nonsense in the bay.
it has not caused me any problems, the experiment, so far, but the constant worry that someday it might knock out some component within the bay has kept me on edge, and i give up.

why i have made this final attempt is cos i spoke to ford guys for a new air box assembly, and it will only be available after about a couple of weeks.
cost, roundabout 4k.
so, that is coming back, and i am making do with this for now.

so all future hopefuls, forget a DIY, and get it done from auth places, or stick to OEM.

DIY RIP.....

[Sankar]

Mayank, man it doesn't look good to me. Try to get custom piping made for the intake to get it installed like what Frank did for his Fiesta. That, while not the best, is much much better than what you have now.
But why did you give order for a new stock airbox? You have the stock airbox and i can see it in the pic, or did you cut it out?

[norevlimit]

Originally Posted by mayankk

theoretically formulated as of now.....just cant find an aluminium pipe bender, or the pipe for that matter.
gonna be a DIY of sorts now, in january.
Involves a 3' 2.5" ID pipe,or a silicone hose, removing the airbox, sand, a blowtorch, and some flat steel bolt holders....will update.
currently its still as above, but not aesthetically pleasing or giving any peace of mind....

Hi dude, try removing to air filter assembly. its an easy job, just unbolt the 2 screws and undo the breather pipe,and give it the shove, see for your self how much of space it would liberate, and then you can easily make up your mind on how you would want to route it,try not taking it to much at the back, because of the exhaust, that area would be hot and would defeat the very purpose of CAI, sorry I don't have THE pics. BUT HAVE TRIED IT. THE SPACE LIBERATED WILL SURELY GIVE YOU A LOT OF IDEAS

[mayankk]

Originally Posted by Sankar

Mayank, man it doesn't look good to me. Try to get custom piping made for the intake to get it installed like what Frank did for his Fiesta. That, while not the best, is much much better than what you have now.
But why did you give order for a new stock airbox? You have the stock airbox and i can see it in the pic, or did you cut it out?

I believe frank had a bolt-on K&N kit, and that basically follows the same lines, but with a smaller filter.
And like i said, this is just a make-do for the next two weeks.
and yes, you see the airbox, the remains of it.
Its just the top sheet of ABS from the original airbox.
I cut it up cos
1. I had already messed up the intake the first time i started trying to find a spot,and ford policy dictates buying the whole assemply, no piece meal basis.(smart guys!!)
2. needed some sort of shield between the pipe and engine head and wires.


PS: its not as bad as it looks, you know.Throw a despondent guy a line!

Originally Posted by norevlimit

Hi dude, try removing to air filter assembly. its an easy job, just unbolt the 2 screws and undo the breather pipe,and give it the shove, see for your self how much of space it would liberate, and then you can easily make up your mind on how you would want to route it,try not taking it to much at the back, because of the exhaust, that area would be hot and would defeat the very purpose of CAI, sorry I don't have THE pics. BUT HAVE TRIED IT. THE SPACE LIBERATED WILL SURELY GIVE YOU A LOT OF IDEAS

trust me, the airbox has been removed and put back so many times, it must think it joined the army or something!!
yes, removing it liberates a lot space, but exposes too much of the innards to be
1. safe(in case the filter gets knocked about)
2. aesthetic

so, cut out the top sheet from the airbox,then cut it again to just about cover the plug junctions, and thats what you see....just about 3-4 mm of ABS.

So in the last 6 moths i have tried the car with
1. OE
2. Optimally placed, but delicate
3. Long-ish, twisty, but robust.
4. No filter!!(for about 10 minutes)

And you know what?
mostly MHP.
2, 3 and 4, all produce some awesome induction noise at about 2k onwards.
but i have noticed that my getaway times from the gurgaon expressway tollgates take approximately the same time.

and the FE remained spot-on the same(except for the no filter bit,where within 10 minutes of me noticing something is wrong, the DTE skipped down by about 50kms)



awesome sound, but now i shall roll up the windows, cos as it is its too cold in delhi...

by the way, would you guys mind sharing some pics, so that i can cry over lost labors of love?

[Sankar]

Originally Posted by mayankk

I believe frank had a bolt-on K&N kit, and that basically follows the same lines, but with a smaller filter.
And like i said, this is just a make-do for the next two weeks.
and yes, you see the airbox, the remains of it.
Its just the top sheet of ABS from the original airbox.
I cut it up cos
1. I had already messed up the intake the first time i started trying to find a spot,and ford policy dictates buying the whole assemply, no piece meal basis.(smart guys!!)
2. needed some sort of shield between the pipe and engine head and wires.


PS: its not as bad as it looks, you know.Throw a despondent guy a line!

No, his bolt on K&N kit wasn't great and thus he was planning on selling it, but after that he got a custom pipe fabricated and relocated the filter and now it looks (and hopefully works) much better.

[mayankk]

Originally Posted by Sankar

No, his bolt on K&N kit wasn't great and thus he was planning on selling it, but after that he got a custom pipe fabricated and relocated the filter and now it looks (and hopefully works) much better.

Really?

How was it not "great"???
i thought it was the one developed specifically for the fiesta?

BTW, saw your work on the A-star.

how much of a difference with the proper CAI?
i mean , whats the noise and performance level change?

Jeez, i cant just give up!!!!

[Sankar]

Originally Posted by mayankk

Really?

How was it not "great"???
i thought it was the one developed specifically for the fiesta?

Based on his views. I though you must've read it.

Originally Posted by mayankk

BTW, saw your work on the A-star.

how much of a difference with the proper CAI?
i mean , whats the noise and performance level change?

Noise is there but low, it doesn't get into the cabin as much as an open element filter would.
Performance is much better compared to the stock setup with replacement panel filter.

[mayankk]

Originally Posted by Sankar

Based on his views. I though you must've read it.

Thats where i goofed up...
The filter i got was much bigger.
Didnt bother taking some rudimentary measurements before ordering.
anyway, cheerios, and thanks.

[CPH]

Originally Posted by mayankk

ok.
so the earlier setup was creating a lot of problems,even if it provided the shortest route for the air.
1. Filter constantly nestled against the ECM.
2. Kept getting detached at the throttle body(i think).

got myself a about 2-3 feet of ABS tubing,2" dia.
heat bent it to get a slight curve going, and wrapped in aluminium foil tape.
the highly acute bend in the pic is not really acute, but 90 degs.
yes it disrupts airflow, but you will see method in the madness soon.
flexible rubber sections of about 4" length each keep the hoses attached to each other and the filter.
the roar has gone down drastically.
filter hangs free now, not touching anything.
the support for the filter is attached the original bolt spots for the airbox.
as for the airbox, well it exists within the bay, as you can see.
what you see is the original airbox cut up to donate its top-layer, the one that says "ford" etc..
this is for heatshielding and for aesthetic purposes.


Sorry about the pic quality,just.
Madness is done, now the method.

See,this has turned out to be more of a headache than i thought possible.
either my filter is too big,or ford seriously do not want nybody doing some sort of nonsense in the bay.
it has not caused me any problems, the experiment, so far, but the constant worry that someday it might knock out some component within the bay has kept me on edge, and i give up.

why i have made this final attempt is cos i spoke to ford guys for a new air box assembly, and it will only be available after about a couple of weeks.
cost, roundabout 4k.
so, that is coming back, and i am making do with this for now.

so all future hopefuls, forget a DIY, and get it done from auth places, or stick to OEM.

DIY RIP.....

Unfortunately this is the worst you could have done.

The only way to realistically gain is similar to the attachment. The filter needs to sit lower, which would be just below the ECU.

[abhipuru16]

Originally Posted by mayankk

Thats where i goofed up...
The filter i got was much bigger.
Didnt bother taking some rudimentary measurements before ordering.
anyway, cheerios, and thanks.

Why don't you take help from Speedsport?
Even I am thinking of Performance mods for my Fiesta 1.6S and I might as well take it up with Speedsport, I heard they are very good.

[mayankk]

Originally Posted by CPH

Unfortunately this is the worst you could have done.

The only way to realistically gain is similar to the attachment. The filter needs to sit lower, which would be just below the ECU.

How?
performance wise?
I'll give you that.
Unfortunately, this is a daily drive, and not a project vehicle.
It had to be made motorable for another 2 weeks as i said.

Originally Posted by abhipuru16

Why don't you take help from Speedsport?
Even I am thinking of Performance mods for my Fiesta 1.6S and I might as well take it up with Speedsport, I heard they are very good.

hmmm!
stop giving me ideas!!
kiddin'...
maybe, sometime later when i get bored with the OEM again.
why dont you go ahead with this.
or pm me.
whenever you go, i'll pop in, and see what's being done, and .....who knows?

damn this bug is unrelenting!!

[mayankk]

Originally Posted by CPH

Unfortunately this is the worst you could have done.

The only way to realistically gain is similar to the attachment. The filter needs to sit lower, which would be just below the ECU.

Hey CPH,
well, I'm going to make one last ditch effort here.
just wanted to know.
which placement is better, the one professed by the 57i, or the one where it currently sits in my pictures above?
excluding the pipes that i have put, of course.

The 57i placement doesnt allow me to use the current spectre filter.I'll have to go in for the smaller k&N.
Dont wanna spend all that, and then decide to spend some more cos i want the OE box again.

i was planning to run the TB-to-filter hose like your layout, and mount the filter in the space next to the battery.

Also, also, doe sthe 57i come with all hoses, or do some OE part have to be reused in that?

Thnaks, man.

[niranjanrvce]

Man that looks a little messed up.
Mayank, did you try placing the filter in the slot where your OEM air intake sits - right behind the left front headlight? I have a CAI installed on my Fiesta 1.6 and my intake is running in from this slot. My CAI was done by RRP and wasn't a DIY so don't really know the effort in getting it there.
Also, the hood door does not obstruct although I have the closed filter sitting right under the latch so I don't get why your very first pic in this thread didn't work out. So far, of all the things you have tried, that one seems to be the best option.

[mayankk]

Originally Posted by niranjanrvce

Man that looks a little messed up.
Mayank, did you try placing the filter in the slot where your OEM air intake sits - right behind the left front headlight? I have a CAI installed on my Fiesta 1.6 and my intake is running in from this slot. My CAI was done by RRP and wasn't a DIY so don't really know the effort in getting it there.
Also, the hood door does not obstruct although I have the closed filter sitting right under the latch so I don't get why your very first pic in this thread didn't work out. So far, of all the things you have tried, that one seems to be the best option.

Share a pic,please?

Although, that first installation is what i am trying to get to again.
Just cant get the right pipes.
That first installation was done very haphazardly by a so called professional installer.
the problem was :
1. It kept fouling with the latch.
2. The pipe kept popping off the TB.(good noise and pick up, but greased up the valve in 10-15 seconds flat!!)

so, in the interim, had to make something, and thusly.....

[niranjanrvce]

Why don't you try sourcing silicon pipes? I know RRP has them for sale. They did have some difficulty getting a perfect fit for the TB - apparently Fiesta's TB is of a little uncommon diameter - but it did fit in the end. And works like a charm!
A pic will explain better, will take one and post it in the night.