A Problematic Free-Flow !!!

dustDevil · 28th June 2006, 22:12

I bought a free-flow for my Zen(carb) from auto-mech... there are a few problems that i am facing:
1. The exhaust-part that just follows the manifold is much lower than the stock one, reducing the clearance by almost an inch! it'll be the first thing to hit any obstacle getting under my car. will it break easily.... do you think i should get a new unit to replace this (though it'll be very cumbersome)?
2. It almost touches a body part (about 4-5mm from it) just below the gear lever. So whenever it vibrates, the vibrations are transmitted to the body.... will filling silicone gel in the gap solve my problem?
3. a part of the intake manifold touched the "cross"(well thats what the mechanics called it) that it passes through so i got abt 3mm of it cut, to enlarge the hole.... hope it wasn't a bad move!?
PLEASE HELP....

a4_attitude · 29th June 2006, 00:08

I Believe the problem is of installation,
I agree it reduces the clearance, but it must not by hitting road so often though on indian roads you can expect anything,
there are some ways out..
first is checking the installation from bottom , you got to check in garage where they have car lifts,
about Filling I think silicon gel may melt due to exhaust heat
that 3 mm is the not worry issue,
one jugaad i can suggest here to raise up ur car by adding 1"- 2" thick rubber to suspension..
Cheers
Wadhwa Ajay

viper · 29th June 2006, 08:06

Hi,
The problem is a misaligned installation. Get it reinstalled and your problems should be solved.

Viper

killjoy · 29th June 2006, 09:47

did you cut your cross member?

dustDevil · 29th June 2006, 10:07

No, nt exactly the cross-member....... cross-member is the part on which the steering rack n' pinion is bolted.... right!? The part i cut is in the front, just below the radiator. i'll post a pic soon...

humyum · 29th June 2006, 11:54

Cross member is place where the engne rests.Engine is supported by engine mountings too.The part u said u cut below the radiator is the cross member.

headers · 29th June 2006, 14:12

Quote:

Originally Posted by a4_attitude

one jugaad i can suggest here to raise up ur car by adding 1"- 2" thick rubber to suspension..
Cheers
Wadhwa Ajay

I thought the handling goes for a toss if you do that!! Are you sure you could?? The best would be to reinstall the headers..

dustDevil · 29th June 2006, 16:00

okay...... so u cud say, i enlarged the hole in the cross-member (through which the exhaust pipe passes) by about 3mm..... is it gonna have any adverse effects?

dustDevil · 29th June 2006, 20:33

1. This is the pic of the first cut: taken frm under the car.... blue thing is the manifold:
http://imageshack.in/img1/index.php/...thumbnail=true

2.This is the second cut: pic taken from above...
[COLOR=#22229c]http://imageshack.in/img1/index.php/...thumbnail=true[/COLOR]

I'm still to give it a bit of finishing and apply paint to prevent rusting! should i use an epoxy paint or oil-paint should do?

harish_303 · 29th June 2006, 20:41

Hey any 1 intrested in nos kit for any car. ask 9423210828

jkdas · 29th June 2006, 22:57

Quote:

Originally Posted by harish_303

Hey any 1 intrested in nos kit for any car. ask 9423210828

try the market place

28th June 2006, 22:12	#1
dustDevil BHPian Join Date: Jun 2006 Location: Surat Posts: 159 Thanked: 16 Times View My Garage	A Problematic Free-Flow !!! I bought a free-flow for my Zen(carb) from auto-mech... there are a few problems that i am facing: 1. The exhaust-part that just follows the manifold is much lower than the stock one, reducing the clearance by almost an inch! it'll be the first thing to hit any obstacle getting under my car. will it break easily.... do you think i should get a new unit to replace this (though it'll be very cumbersome)? 2. It almost touches a body part (about 4-5mm from it) just below the gear lever. So whenever it vibrates, the vibrations are transmitted to the body.... will filling silicone gel in the gap solve my problem? 3. a part of the intake manifold touched the "cross"(well thats what the mechanics called it) that it passes through so i got abt 3mm of it cut, to enlarge the hole.... hope it wasn't a bad move!? PLEASE HELP.... Last edited by dustDevil : 28th June 2006 at 22:13.
	() Thanks

29th June 2006, 08:06	#3
viper BANNED Join Date: Mar 2005 Location: Mumbai Posts: 1,773 Thanked: 19 Times	Hi, The problem is a misaligned installation. Get it reinstalled and your problems should be solved. Viper
	() Thanks

29th June 2006, 09:47	#4
killjoy BHPian Join Date: Jun 2004 Location: Bangalore Posts: 753 Thanked: 317 Times View My Garage	did you cut your cross member?
	() Thanks

29th June 2006, 10:07	#5
dustDevil BHPian Join Date: Jun 2006 Location: Surat Posts: 159 Thanked: 16 Times View My Garage	No, nt exactly the cross-member....... cross-member is the part on which the steering rack n' pinion is bolted.... right!? The part i cut is in the front, just below the radiator. i'll post a pic soon...
	() Thanks

29th June 2006, 11:54	#6
humyum Senior - BHPian Join Date: Feb 2006 Location: Mumbai Posts: 2,751 Thanked: 5,425 Times	Cross member is place where the engne rests.Engine is supported by engine mountings too.The part u said u cut below the radiator is the cross member.
	() Thanks

29th June 2006, 00:08	#2
a4_attitude BHPian Join Date: Sep 2005 Location: New Delhi Posts: 508 Thanked: 101 Times View My Garage	I Believe the problem is of installation, I agree it reduces the clearance, but it must not by hitting road so often though on indian roads you can expect anything, there are some ways out.. first is checking the installation from bottom , you got to check in garage where they have car lifts, about Filling I think silicon gel may melt due to exhaust heat that 3 mm is the not worry issue, one jugaad i can suggest here to raise up ur car by adding 1"- 2" thick rubber to suspension.. Cheers Wadhwa Ajay
	() Thanks

29th June 2006, 16:00	#8
dustDevil BHPian Join Date: Jun 2006 Location: Surat Posts: 159 Thanked: 16 Times View My Garage	okay...... so u cud say, i enlarged the hole in the cross-member (through which the exhaust pipe passes) by about 3mm..... is it gonna have any adverse effects? Last edited by dustDevil : 29th June 2006 at 16:06.
	() Thanks

29th June 2006, 20:33	#9
dustDevil BHPian Join Date: Jun 2006 Location: Surat Posts: 159 Thanked: 16 Times View My Garage	1. This is the pic of the first cut: taken frm under the car.... blue thing is the manifold: http://imageshack.in/img1/index.php/...thumbnail=true 2.This is the second cut: pic taken from above... [COLOR=#22229c]http://imageshack.in/img1/index.php/...thumbnail=true[/COLOR] I'm still to give it a bit of finishing and apply paint to prevent rusting! should i use an epoxy paint or oil-paint should do?
	() Thanks

29th June 2006, 20:41	#10
harish_303 Newbie Join Date: May 2006 Location: pune Posts: 3 Thanked: 0 Times	Hey any 1 intrested in nos kit for any car. ask 9423210828
	() Thanks