Hey Guys,
Just thought I'd update you on what's happening.
I had ordered a complete bolt-on FFE for my Getz from viper. He sent it to me by courier....took a couple of weeks to arrive.
A BIG thanks to Jerry (jerish666) who introduced me to the mechanic (the garage was on the NH bypass near Chackai).
Ok, so on Friday morning I went to the garage with the FFE to get it fitted.
I faced a lot of trouble with the FFE.
1) There were no gaskets or bolts in the kit I received. Just the pipes were there. I was expecting that atleast the gaskets would be provided. Jerry took me to a spare parts shop in Karamana (Swaraj) where we got the gaskets and the bolts.
2) When I went back to the garage, I was in for a small shock. The pipes wouldnt fit properly. The bending of the pipes were incorrect; the joints between the pipes would'nt fit properly; a whole lot of bending, cutting and welding was required. The whole thing took atleast 4-5 hours. The mechanics told me they hadn't had to do this much welding for any FFE ever. I was thinking of calling up Jignesh, but then I thought - what's the point. He's in Mumbai, I'm in Trivandrum- no use complaining now.
3) After all the cutting and welding we managed to fit the darn thing, I was relieved I could go home now. We started the car, and I was in for shock # 2. Viper told me the car would be a little louder than stock. I repeatedly told him I wanted a very sedate exhaust note ; he said "dont worry, it'll be 5 to 10% louder than stock below 3000 RPM". Well...I'm sure somebody missed the percentage part, coz it was like 5 to 10 times louder than normal. There was NO way I could drive around in the car with that exhaust. I have seen and driven cars with FFEs, but MAN, this was WAY too loud. And it wasn't the kind of sexy deep sound you normally expect from an FFE. It sounded like a torn silencer. Imagine an old premier padmini with a 10X amplified exhaust note - that's more like it.
4) To top it all, there was a leak near the exhaust manifold (where the header is joined to the cylinder block). It was too late into the night, the mechanic said "bring it back, we'll fix it next time".
One more thing - I noticed the stock exhaust system had an "expansion chamber" or "mid-muffler" between the cat-con and the muffler. I'm not sure of it's function, but the mechanic told me it is important for sudden acceleration. Viper's exhaust just had a straight pipe instead of the expansion chamber - not sure why.
Anyways the very next chance I got ,I went back to the garage and asked them to put back the stock expansion chamber and muffler. Instead of the manifold, I retained Viper's header. So now it was custom header + stock expansion chamber + stock muffler.
This time, they were able to solve the exhaust leak also. It was a problem with the header. The top portion of the header was touching the cylinder head (or whatever it was), so it wasn't fiting properly. Again they did some filing and now the exhaust leak was also solved.
Started the car again. Phew..what a relief. Sound was back to almost stock. Power was also quite good. Not as powerful as when I had the torn silencer thing, but still it was suprisingly good.
I had plans to get in an air filter + some better end can. I was expecting that power wouldnt be so good. But just with the headers ( and with the stock air filter and muffler), driveability has increased very much. The car pulls nicely from low revs (which is what I wanted). It's also more free revving now. Overall I'm very happy with the way it's driving now. I'm actually quite surprised that just a header can make such a difference. If so, this mod should be done to every Getz. I didnt try a PUC check yet. I hope it'll pass.
Anyways that's the story till now. All's well that ends well. And I learnt quite a few lessons in the process
I read thorugh a lot of posts about FFEs, but never read about anyone having so much trouble with one. So either it's just me, or people are just keeping quiet. Dunno..anyways...thanks for reading.