[PratikPatel]

Couple of additional photos of the hub that we had to custom create for the steering.

[antonjeeper]

Hello Prathik Sir,

Any new updates on your car? Many of us are eagerly waiting for your updates on that Duratec Ford!

[PratikPatel]

Originally Posted by antonjeeper

Hello Prathik Sir,

Any new updates on your car? Many of us are eagerly waiting for your updates on that Duratec Ford!

Major updates coming up next week

[motorpsycho]

Hello Pratik, Any update on this project? I was also interested in knowing how the plasma booster was wired to work with the new Tower.

[PratikPatel]

Custom made Carbon Fibre CAI (Cold Air Intake)

Before I start with the captioned subject, we are back to working on the car after long hiatus, partly enforced by the Covid 19 pandemic and partly due to other circumstances that were beyond our control. However, we back with a number of updated items lined up.

The car has now completed over 20,000 kms with the updated head, valves, cams, ignition and remap. It has been working flawlessly without any problems in these areas. The car pulls cleanly up to 7,000 rpm and is an absolute pleasure to drive. It has shown itself to be as reliable as a stock build.

As one of the changes even before we embarked upon the project the car was fitted with Pipercross Air Pod in place of . After 3 years of running, the sponge of the filter element had started breaking down and it was effectively the end of the life of the air filter. It was time to replace the filter and the first impulse was replace it with new Pipercross air pod. However, after giving it some thought Vikram suggested that we replace the stock air intake system into a Cold Air Intake. He recommended that he will make one and that I would not be disappointed the results.

I got a call from Vikram a month after the discussion letting me know that system was ready for installation. I drove down to Pune over the weekend to get the system installed.


Resonant Air Box

Duratech engines come fitted with an air intake system that consist of a air filter box that feeds fresh filtered air into a huge air box that acts as a resonator. We had removed the air filter box and fitted a air filter pod in its place. To install the CAI we would need to remove the resonant air box and feed air directly into the throttle body from the air filter pod.

The role of resonant air box is 2 fold. Firstly, to reduce noise created by air intake and secondly, to provide positive air pressure that assists in air induction into the throttle body.

In the early 70s, the governments of the western world started looking at legislation to reduce vehicle noise and pollution. This led to exploration of ways to reduce engine noise. The air intake system make a significant amount of noise. Sound is created in waves by pressure pluses created during natural aspiration of the engine. Pistons create a partial vacuum to pull in air during the intake stroke, this leads creation of a low pressure pulse in the air box. From then on the during the next processes of compression, power and exhaust the intake valves are closed, thereby the air box returns to atmospheric pressure. These hundreds and thousands of alternating low pressure and normal pressure pluses generate sound energy waves.

To reduce the intake noise, car makers needed to dampen these energy pluses out. Thus, a big chamber that can hold air and allow for air to be inducted into the engine at a controlled rate was required.

Air is compressible, this fact along with big box makes for a something akin to energy storage device like a capacitor or spring.

All modern engines have valve overlap and with NA engines there will be drop or flat spot in the torque somewhere between one third or half way to the redline rpm of the engine. This is inevitable in a NA engine. A resonating air box can be tuned to partially fill in this dip in torque curve, thus the air box can be designed to boost power in the mid rage, however it will have no effect of peak HP. It is most likely that if your car has a resonant air box its tuned to boost the midrange of power curve.

It is also a popular myth that a resonance box hampers power generation and thus needs to be removed to gain extra power. The fact is that modern resonance boxes are so well designed that they can flow much more air than the engine will ever need.

The inside of a resonance box looks like a complicated labyrinth through which air works its way through to the inlet track.

This complicated design is worked out in close conjunction with design of engine. The cams, inlet track, valve sizes, engine cubic capacity, all play an important role in the design of the resonance air box. Therefore, it is not advisable to remove the air box in search of more power and air flow with a stock engine. You are likely to loose some significant midrange and gain virtually nothing at high range and peak power.

Change any of the above mentioned engine parameters and the effective design of the resonance air box is no longer valid of the said engine. If the parameters are radically changed then the air box will need to replaced with a redesigned air box or new air induction system.

Thus, thought it was time to see what effect will a cold air intake system have on the changes we have made to the engine till date.


What looks like engine cover is actually a resonator air box. (Pardon the filthy engine bay. The car has been sitting unused for past 6 months)


Worn out Pipercross filter attached to the resonator air box.

Cold Air Intake

Vikram created a custom made cold air intake where the housing of the air filter element is made out of carbon fibre. It looks gorgeous and stunning. The kit consist of a carbon fibre made housing with a air filter element, silicon rubber joints, accordion type cold air intake pipe, and clamps.


Custom made CAI Kit.


Air Filter Element


Accordion Type Cold Air Pipe

Frankly, when Vikram had said he would create a custom CAI, I thought it would be some rough jig, however looking at the whole setup, its looks a finish product from some reputed brand.

Installation

The installation of the CAI was fairly simple and straightforward. Removing the resonator air box require removing 2 bolts and loosening the clamp on the hose that connects the air box to the throttle body.

As you can see the top resonator air box is designed to look like a engine cover. The crankcase breather tube is also connect to the resonator box. When the box is flipped, from the bottom it looks like the resonator box has 2 chambers, a primary and a secondary one. At the time we did not have time to explore it further, but will definitely open it and see what’s the design logic behind the whole thing at a later date.


Resonator Air Box (its fairly huge!).


Ready for installation of CAI.


Carbon Fiber Air Filter Case.


Stabilising the joint by inserting a titanium ring (Why titanium? Because there was one laying around )
.


Perfect fitting.


Pipercross Crankcase Breather Filter.




Final Assembly

The installation was also fairly simple as Vikram had all the parts and it all fit together perfectly.

After installation, I returned back to Mumbai in the evening, and the whole setup was running flawlessly. There is a increase in the intake roar and the car is that much bit more free revving. One instantaneous change was in the ‘distance to empty’ range; the figure jumped by 25 kms (was showing 200 kms when I started back) after a few kilometres of running to. On the whole its not going to lead to any earth shaking increase in performance, but the small gains all add up at the end of the day.

[viXit]

Originally Posted by PratikPatel

Custom made Carbon Fibre CAI (Cold Air Intake)

Before I start with the captioned subject, we are back to working on the car after long hiatus, partly enforced by the Covid 19 pandemic and partly due to other circumstances that were beyond our control. However, we back with a number of updated items lined up.

You have no idea how excited I was to see a new post here. The wait was painful. I truly love this thread!!

Waiting for more and more posts!

[Arka Saha]

I went through the entire thread and I was amazed to see the level of detail that has been put across for each and every change/update.

Looking at the level of detail being shared, I felt this would be the perfect place to put forth my situation.

So a friend of mine recently bought a 2011 Fiesta 1.6 Duratec (ZXI) and atleast for now (due to budget constraints) he wants to upgrade the entire suspension setup, alloy wheels and steering rack to that of the 1.6 S. However he is not a member of teambhp. As a result, I am having to write this on his behalf. He has reached out to Mukesh Ford (Kolkata) asking for the parts specific to that of the 1.6S. And he plans to get the work done from Alok Automobiles. However Mukesh Ford is unable to assist him without the model specific part numbers for the above mentioned updates.

Hence, it would be extremely helpful if someone could shed some light on this topic and help my friend out with the upgrade by providing the model specific part numbers if possible.

Additional advise is always welcome.

Thanks in advance!

[Avinash_R]

Originally Posted by Arka Saha

So a friend of mine recently bought a 2011 Fiesta 1.6 Duratec (ZXI) and atleast for now (due to budget constraints) he wants to upgrade the entire suspension setup, alloy wheels and steering rack to that of the 1.6 S. However he is not a member of teambhp. As a result, I am having to write this on his behalf. He has reached out to Mukesh Ford (Kolkata) asking for the parts specific to that of the 1.6S. And he plans to get the work done from Alok Automobiles. However Mukesh Ford is unable to assist him without the model specific part numbers for the above mentioned updates.

Thanks in advance!

The shock absorber part numbers can be seen in the attached images. Those are from my S and was fetched for a friend who wanted suspension swap for his fiesta. I don't have the car with me now though.

Edit: Seeing that you are in Bengaluru, you can see my old car with my BIL to get any other details you want. It's a 2008 Fiesta 1.6S.

[Arka Saha]

I am not in Bangalore as I am currently working from home in Kolkata. Would be helpful if you could tell me what you mean by BIL.

[Arka Saha]

My friend has recently bought 2008 Ford Fiesta 1.6S. However, the instrument cluster in the car seems to be malfunctioning. Got it checked from Ganges Ford Kolkata and they are suggesting we get it replaced. The problem is that the cluster for the 1.6 is different from that of the 1.6S. The Service Center is saying that they cannot assure whether the one available with them is the one for the 1.6S.

In this situation, it would be helpful if someone could help us find the right replacement cluster.

I have attached pictures of the 2 different clusters.

The one with the silver surround around the dials is the one used in the 1.6duratec and the one with the black surrounds is the one for the 1.6S.

[venkat_partha]

Wow! A dedicated Fiesta Thread!

I have a 2006 Fiesta ZXI (stock, no mods) that has clocked over 1.18 L KMs. I have just renewed the FC and intend to keep it running for as long as it is feasible.

This thread is certainly a hoot to read!

[dipen]

Originally Posted by Arka Saha

In this situation, it would be helpful if someone could help us find the right replacement cluster.

I have attached pictures of the 2 different clusters.

The one with the silver surround around the dials is the one used in the 1.6duratec and the one with the black surrounds is the one for the 1.6S.

The one with the silver surrounds looks better and more matching with the rest of the interior theme. The Black one is actually looking bland.

[anachronix]

The one in the 3rd pic is from the S. Hope that helps.

Originally Posted by Arka Saha

My friend has recently bought 2008 Ford Fiesta 1.6S. However, the instrument cluster in the car seems to be malfunctioning. Got it checked from Ganges Ford Kolkata and they are suggesting we get it replaced. The problem is that the cluster for the 1.6 is different from that of the 1.6S. The Service Center is saying that they cannot assure whether the one available with them is the one for the 1.6S.

In this situation, it would be helpful if someone could help us find the right replacement cluster.

I have attached pictures of the 2 different clusters.

The one with the silver surround around the dials is the one used in the 1.6duratec and the one with the black surrounds is the one for the 1.6S.

[TwistyWristy]

Has been quite some time. Any updates?
I hope there are some. I am Too invested in this.

P.S. Making of Ninja-San was one of the best thing I ever read