[Swarup5]

Originally Posted by Leoshashi

Miscellaneous points regarding Stage 1:


-The doors close with a nice thud now.

-External noise with windows closed is completely gone, love how everything outside feels muted now. Horns are audible, and that's it! Even cars costing thrice as much feel lacking in this department now. Have turned XL6's weakness into it's strong point. A new Ertiga/XL6 or even my Crysta feels so basic now in terms of NVH.

Feel free to ask any questions.

Regards,
Shashi

Excellent job Shashi and kudos to your installer who has done it so patiently . Totally agree with the results and I can relate with my recent damping done on Honda city 5G. Do get the stock speakers upgraded with options like JL audio/ Audison and see the difference it makes . I could clearly see a huge difference with just the damping and speakers upgrade ( needless to say they were plug and play ). Disappointing to see why companies give speakers which are like toys even on cars which cost a good 1-2Mil.

[Leoshashi]

Originally Posted by MadTiger

For example usually Damping sheets are applied on the outer metal sheet completely, but I choose to customise and not apply areas were there are nuts and bolts which may require access during component failure (usually don’t).

Great job. The stock insulation of these cars is so average that any kind of upgrade will show its effectiveness. And the job you did, is enough to arrest vibrations, external noise etc.

Regarding your logic on bolts/screws access during component failure, it's a good thought, but the sheets will be disturbed if access to those are needed. Say we need to get access to window winder mechanism, the sheets will have to be peeled off. Thus to save time and effort, plus with the added advantage of better coverage, I decided to go with complete coverage within the OE butyl boundary.

Originally Posted by Swarup5

Do get the stock speakers upgraded with options like JL audio/ Audison and see the difference it makes .

I agree, speakers do need an upgrade. These JBL coaxials are a stop gap measure, because I got them for just 1000 rupees after exchanging the stock ones which were a joke TBH. Thus made tremendous sense. This is exactly why I've not installed any accessories like rainguard, rings etc. JBLs will go soon.

The issue with taking recommendations from anyone regarding audio/speakers is that music is a very personal thing. The profile one likes may not be the same which I do. So unless I get to experience these setups personally, it's impossible to pass any verdict or invest money on a particular setup.

Hope to meet BHPian Madtiger soon and experience the setup on his XL6.

Regards,
Shashi

[Leoshashi]

Originally Posted by Leoshashi

It was done in two stages. Stage I involved insulating the Doors, A Pillars and Roof. This was done last year, in August 2020 I guess. Stage II took care of Floor and Rear Quarter panels which was done in October 2021.

Stage 2 Update: I decided to postpone it, only since the floors atleast had some kind of insulation, unlike doors and roof which were entirely naked. However a quick comparison with some well built Suzukis like Kizashi, or the Ciaz whose stock insulation feels superior to other Marutis revealed that XL6 had negligible damping on floor panels.

OEMs use Melt sheets(that black thick tar like stuff) for damping floor panels. Here is a comparison of different Marutis:

Kizashi:

Ciaz

Heck Ciaz has some damping on roof as well

Ertiga Petrol:

Ertiga Diesel:

XL6 in comparison, got even lesser silencer material on floor than Ertiga, due to different mounting holes at rear for captain seats:

Not only did XL6 get lesser damping than something say Kizashi, even sheet thickness was low. XL6 got 1.5mm sheets, while Kizashi got as high as 3mm at some locations.

Trouble areas: I specially wanted to cut noise from rear wheel arch which was very prominent on cemented roads like GT road. Also had planned to damp the entire floor section, but was absolutely unaware of what was waiting for me. Read on!

Sheets Used:

1. STP Black Silver series, 1.8mm. Sourced from AudioConcepts, 98713 32377

2. Dr Artex Lace Foam Sheets

Steps(Easier said than done):

1. Disconnect Main battery terminals. Both positive and negative.
2. Remove Front and Middle row seats. T40 socket will be needed.
3. Disconnect Auxiliary Power module:

4. Remove Boot tray and carpet and subsequently remove last row seats.
5. Remove Rear quarter panel pads.
6. Remove Center console
7. Install sheets and then Fit everything back

Thankfully I had Arjun by my side, and he had come at 6am to start early. We did it during the Dussehra Holidays so that we had ample time at hand. Thanks to his accurate and fast hands, we managed to complete the job by evening.

Process for each panel was a standard affair. Clean with IPA, Cut sheets as per size while being mindful of mounting holes, press and roll with the roller.

Time for pics:

The expensive Li Ion battery, costs north of 55k today:

Exposed terminals:

XL6 employs these thick thermocol bases to raise the platform effectively. They are almost 2 inches thick and well built:

Rear AC's pipes:

Thankfully, the stock carpet was pretty thick!

Parts lined outside:

Naked floor, notice the minimal stock damping:

Process begins:

We used this screwdriver to raise the dash panel damping:

IPA Wipedown:

Closer look at the complex Rear AC piping:

Front Floor done:

Supplies:

Mid floor done:

Another look:

Namesake insulation on tail panel:

Naked Quarter panel:

Rear floor and quarter panel damped:

Noise insulator applied on the plastic quarter panel trim:

Thermocol platform going back in:

"Headache" is back in, safely:

Aftermath: I was expecting a drastic decrease in road noise, and nothing much. In reality, road noise decreased a bit, specially the noise from rear was gone. But what shocked me was the difference in suspension behavior. All the vibrations which got transferred from suspension to front floor was completely gone. XL6 felt to be riding much plusher and in an elegant way. All the harshness and vibrations on sharper undulations was gone! Even the drone from engine decreased a bit, perhaps it was travelling down the undamped panel and this insulation eliminated it. Highly impressed.

[Leoshashi]

Small yet significant points:

1. I ended up spending almost 50k in the entire insulation job(doors, roof and floor). This includes supplies like sheets, clips, wax, Arjun's labour plus food expenses. But the difference made it all worth!

2. Weight added to the Shell: 48kgs. This has been calculated from the total number of sheets added and weight of each sheet as given in their data sheets.

3. All bolts and screws were properly torqued as per specs mentioned in the service manual. We also used thread locker wherever instructed:

4. Arjun feasted on delicious Pizza during lunch time. This allowed us enough time to dedicate on the job. Unfortunately I was fasting that day, so had to be a mere spectator:

However I took my revenge the next day, by ordering myself a pizza and sending him a pic :

5. We didn't use old clips anywhere. All clips were brand new and SGP ones from Kizashi, like Stage 1.

6. This gave me an opportunity to clean the carpet deeply before installing it back. After installation, it was vacuumed once more.

7. We did Deoghar trip immediately after this, and the difference was very evident.

With this, the long overdue update on sound insulation is live. Signing off with a recent click of the "rigged" XL6, as fondly called by BHPian Madtiger:

Regards,
Shashi

[MadTiger]

Originally Posted by Leoshashi

Stage 2 Update: I decided to postpone it, only since the floors atleast had some kind of insulation, unlike doors and roof which were entirely naked. However a quick comparison with some well built Suzukis like Kizashi, or the Ciaz whose stock insulation feels superior to other Marutis revealed that XL6 had negligible damping on floor panels.

Originally Posted by Leoshashi

Small yet significant points:

1. I ended up spending almost 50k in the entire insulation job(doors, roof and floor). This includes supplies like sheets, clips, wax, Arjun's labour plus food expenses. But the difference made it all worth!

2. Weight added to the Shell: 48kgs. This has been calculated from the total number of sheets added and weight of each sheet as given in their data sheets.

Regards,
Shashi

Well I knew this was coming . One thing I can say with guarantee that this is the only XL6 in the world that was modded to this level. Puts expensive cars as much as 3 times the prices of XL6 to shame. If Maruti engineers ever get to experience this car they will be thoroughly embarrassed. I was really surprised to see the level of damping in CIAZ. I could have chosen the CIAZ but I don't like sedans for their low seating position.

Even if 50kg was topped to the already 1.7 ton vehicle it would hardly make any difference in real world scenario.

It's only you who makes no compromises in terms of choosing what is good for your vehicles. They are pampered or I must say spoiled to infinity. So 50k expense is just tip of the iceberg.

One lucky XL6 ever produced by MISL after GG. Wish you all the very best and a long association with your "rigged" XL6.

[Kpzonwheels]

Originally Posted by Leoshashi

Attachment 2236156

Ciaz
Ertiga Petrol:

Attachment 2236155

.

Great job . Do you have these diagrams of baleno petrol. If yes please post it here. It would be helpful to understand damping of various MS models.
Thank you

[Leoshashi]

Originally Posted by Kpzonwheels

Great job . Do you have these diagrams of baleno petrol. If yes please post it here. It would be helpful to understand damping of various MS models.
Thank you

Sure, will do. If memory serves me right, Baleno had far more silencer sheet covered area than XL6.

Regards,
Shashi

[PrasannaDhana]

Great work Leosashi!!

Like Dr. Naren is to engine remapping, you are to functional mods.

Originally Posted by MadTiger

. I was really surprised to see the level of damping in CIAZ. I could have chosen the CIAZ but I don't like sedans for their low seating position.

I have always noticed that ciaz NVH (even in diesel) was much better than the SCross and Brezza. Now I know why. It is one refined car to be in!

[universal]

You seem to have missed my post, Shashi.

Originally Posted by universal

Dear Shashi, that is some amazing work.

I seek your advice for a friend's 2019 Ertiga ZDI+, we're considering upgrading the head lamps to white colored HID or LED. Which one would you suggest and what brand?

Also, should we upgrade the fog lamps to the LED ones on the XL6 or Brezza? Or something else?

[umohan98]

Great Work Leo!
Only if these levels of noise insulations could be part of an optional fitment from factory.
Would be interesting to compare noise levels inside your car and an unmodified XL6 using a decibel meter.

How do you get access to these diagrams? Would love to see how the flagship S-Cross is insulated.

[Leoshashi]

Originally Posted by universal

You seem to have missed my post, Shashi.

For best visibility, consider getting Projector Fogs with HIDs.

Originally Posted by umohan98

Great Work Leo!
Only if these levels of noise insulations could be part of an optional fitment from factory.
Would be interesting to compare noise levels inside your car and an unmodified XL6 using a decibel meter.

There is a huge difference when compared to stock XL6, one can easily appreciate the difference while driving, but measurement with a decibel meter is futile since it's impossible to replicate same levels of noise in both cars in regular traffic. Unless it's an even playing ground, how can we compare?

Regards,
Shashi

[anand.shankar]

Outstanding work there @leoshashi! You have some patience...

I'm planning to get some basic damping done on my Scross as well once I get back to Bangalore next week. Initially, I thought I can get it done myself, however looking at the extent of work, I think I'll get some professional help as well to work along with. Unfortunately, I already PVC Wrapped my floor, so only the seat base and the boot floor will be accessible to damp.

Hoping to see some DIYs on your SCross as well

[Leoshashi]

First Balancing and Alignment check: Odo is at 16,952 km. For me WA and WB is entirely need based and I don't like to disturb it unnecessarily, mainly because we don't have reliable alignment centers like Madhus of Bangalore. Here I've suffered in past due to them messing up the alignment. Most centers don't get their equipment calibrated periodically.

Recently I was noticing steering vibrations after 110kmph which is a classical sign of tyres needing wheel balancing. Car was still tracking straight and alignment looked perfect to me. I'm very sensitive in this regard and even a slight issue in alignment comes to my notice immediately.

Visited this store which is near my house, mainly because the technician there is very competent and experienced. They have John Beam equipment, not the Hunter which I prefer, but a competent mechanic is compensates it IMO. Had taken a bottle of IPA, microfiber and my trusted torque wrench.

Lined up for work:

Taking out the pebbles:

Inside of rim where weights stick was cleaned with 50% IPA

Vibration was mainly due to one of the older sticker weights falling off. Got all 4 wheels balanced and the wheel was then torqued to 100Nm:

The technician then informed me that they don't have values for XL6 yet:

I got them the values from Service manual, and it was double checked with the values John Beam support sent him:

The mechanic was shocked, Alignment was still perfect. No wonder I never felt any need. He left it as it is and didn't charge for alignment either:

Regards,
Shashi

[Leoshashi]

Attention all XL6 owners, in addition to New Ertiga, New Swift, Ignis, Dzire and Ciaz: There is a selective recall for our cars. Not all car owners need to be worried. Those who face issues with abnormal engine vibrations, need to get their cars inspected and RH engine mounts replaced FoC.

I repeat, not everyone needs to get this done. Only if you face anything abnormal.

Models: New Ertiga, XL6, New Swift, Dzire, Ciaz, Ignis

Part No, Name: Mounting Comp Engine RH, 11610M72R00

Problem Reported: Engine abnormal Vibration, rubber may crack.

Countermeasure taken: Adhesive grade changed to control gas generation during moulding.

Cut Off VIN:

Ertiga: MA3BNC32SMG361698
XL6: MA3CNC32SMG261516
New Swift: MBHCZCB3SMG838412
Ignis: MA3NFG81SMG319333
Ciaz: MA3EXGL1S00437213
Dzire: MA3EJKD1S00C76583

CutOff Date: 22nd July 2021

Pic of the part:

[mytbhp_turbo]

While this is really "next level" damping, more of "naive" question, every-time i think of car damping, i always get worried whether they will be able to assemble stuff back with same factory quality finish.
Is it unfounded fear ?