Jump to content


Photo
* * * * * 2 votes

"taking Oval To Blue Horizon" Lenny's Build Thread 2010-2013


  • Please log in to reply
679 replies to this topic

#271 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 02 September 2013 - 11:06 AM

Update:

Dpf internal removal with remap will take place on Friday 13th
I will take some pictures of the process if possible and update with a review of gain and fuel economy,

Sadly then that will be the end of a three year project on the focus,
I will still work on the smoothing of the rear door handles and perhaps a set of aluminium pedal covers but that's all.

There's not much point in taking it further in terms of performance,
I use the focus as a family car and daily driver,
There is room for improvement to bring performance up to 150bhp by fitting a hybrid turbo and bigger intercooler with a K&N57s induction kit too.
But this performance from a 1.6TDCi is uncharted territory in terms of reliability.
The results would demand a upgraded clutch, 4 pot brakes and possibly having the gear box pinned and toothed with steel to prevent shredding.
Potentially 8,000euro to have a 100% reliable safe 150bhp 1.6TDCi

Not worth it in my opinion,
And to be honest it has been super fun creating all the guides and feeling the new found performance of remap, egr blank, lowering and increased handling, it has come a long way and I've enjoyed every day of it, you guys have been great supporters throughout the build and in my mind we were out there doing the mods togeather.

The focus 1.6TDCi ticks all the box's for me except for 2

1. It doesn't sound like a performance car, even with a 2.5" piper duplex it grumbles
2. It doesn't exit corners with as much acceleration as I would quite like

Now number 1 can't be helped,
But number 2 I'm guessing if it was a 2.0tdci then I'd probably have a better response, but lowered on eibachs makes handling fantastic hot knife through butter and on 18" Avon ZZ3 sticks to the corners like its abseiling on a rope.

Diesel tuning has been super fun,
But my attention now is on a petrol motor,

Not any old petrol motor,
But a Japanese imported Toyota Corolla Levin BZR AE-111 Coupé
The engine is developed much like ford used to do there sports model escorts
The same engine in the sports car as the road car.
The engine in the Levin is a 1.6 naturally aspirated non turbo
However it was developed by Toyota in partnership with Yamaha as a racing spec engine,
As result its a 178bhp twin-cam 20valve engine which has 4 throttle body's as standard with a 6 speed gear box.
The engine was first built in the mid 80's for drifting competition where it was turbo and supercharged in the Toyota Levin AE-86
The exact same engine was re-released in 1995 when Toyota built the FWD Levin AE-101
Followed by the FWD AE-111 released in 1998 and last built in 2000

Throttle body's are like little trumpets and suck in the air directly from the surrounding atmosphere, no closed induction box or force feed induction, each individual cylinder pulls in its air via the velocity stack trumpet.

This method mixed with a twin-cam petrol engine makes a fantastic engine sound,
And fitted with a 2.5" exhaust system with formation 4-2-1 piping from manifold will make a fantastic smooth low rev sound with a raspy high rev red lining at 9,000rpm when changing down gears going in to tight bends and again when opening up on the exits
Will sound sweet, and ticks the two box's the focus diesel doesn't,

So my new project will be a 1998 upwards white Toyota Corolla Levin BZR
Purchasing in December or early 2014

P1000141.jpg
I plan to keep the focus as the reliable family car which will be used for long journeys etc.
But the Levin will be used to take me to work and the occasional trip in the country,
I will re do some mods on the Levin same as the focus so as there is no loss of driving comforts,
Aux port,
Dual cree reverse,
Mist washer jets,
Foot well lighting,
Illuminated ignition ring,
And some Osram bulbs

Once purchased I will create a build thread called "snagglepuss the story begins" on the AE-111 forum and I'll add a link on here for you guys to view,
Since I will still be a focus owner I will remain on here with you guys sharing my guides and learning from others,
Hopefully some of you can help me along with my new project too.

Have something to contribute?

Sign in or register to start a topic...

Sign up to FOC Premium Membership To Remove These Ads

#272 mixmasterlooney

mixmasterlooney

    The Sexecutioner

  • FOC Supporters
  • 1,673 posts
  • Name: Kurt
  • Ford Model: Focus Zetec S
  • Year: 2010
  • Location: Greater London
Contributor

Posted 02 September 2013 - 08:44 PM

Lenny this sounds like a good bye thread lol not good! I agree with you on the lack of power out of corners, and i too wish i chose the 2.0L

 

 

Stock map on my car and i'm able to keep up with a 2.0L Audi A4 flat out the out barely gets away so with i think it's game over. I totally understand your hunger for more!! go for it i hope you stay on this forum though



#273 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 03 September 2013 - 03:30 AM

Lenny this sounds like a good bye thread lol not good! I agree with you on the lack of power out of corners, and i too wish i chose the 2.0L
 
Stock map on my car and i'm able to keep up with a 2.0L Audi A4 flat out the out barely gets away so with i think it's game over. I totally understand your hunger for more!! go for it i hope you stay on this forum though

Thanks Kurt
I'll still own a ford so I'll be on the forum,
Just an end to me creating any more guides on the forum,
My next guide will be on the AE111 owners club all going well,
I'll be keeping the 4AGE engine in the Levin standard except for a piper induction filter,
And an exhaust system,

Some new things in stir
Pivot mega razin volt stabiliser kit,
ScangaugeII ( so I can see my MPG)
Perhaps a shift light
And an exhaust flamer kit for the laugh

I'll keep in touch
Can't wait to get a run in a Levin though

#274 b4zz

b4zz

    Too much time on the boards

  • True Ford Enthusiast
  • PipPipPipPip
  • 781 posts
  • Name: Barry
  • Ford Model: facelift focus zetec
  • Year: 2009
  • Location: Cardiff

Posted 03 September 2013 - 06:47 AM

glad to hear you have injoyed the jurney with the focus and gota agree it has come a very long way from when you bought it and what a great job you have done.

good luck with the purches of the new (old) car next year and will look forwred to reading all about the changes you make.

Vicki injoy driving the focus



#275 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 13 September 2013 - 06:21 AM



#276 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 13 September 2013 - 06:22 AM

I'm off now for dpf break through at 10am,

And I'll update y'all later with the results, "break on through"

#277 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 13 September 2013 - 03:10 PM

Update:
I've met the lads at MFK Auto Care this morning for DPF internal removal,
And I must say the guys done a very professional job the proof that dpf has been internally removed; can only be seen by the increase in smooth performance and increased MPG, fantastic job done and gives me great future peace of mind.

The guys took great care to ensure the chamber was weld back on along the original seal and all appears like it has never been touched, just like I had requested,

The results afterwards on the journey home were better than I imagined,
No smoke at all from the rear, not even when you floor it in 5th on the motorway, :)

There's a performance increase too,
If I was to describe the increase in performance it would be 3 times the increase in power felt from EGR blanking,

The engine ticks over at lower noise now
And the rev up is much smoother, increased air flow helps reduce turbo lag to almost extinct,
As result gear change is smoother too,
Its all positive, no more dpf no EML lights or fear of one appearing in the future neither.

And the guys were dead sound, didn't mind me watching and asking questions,
I highly recommend MFK Auto Care well worth making the journey and top class work very happy.
http://www.mfkautocare.com/

They also had a look at the ecu map I had previously put on the car and tweaked it a bit resulting in boost coming on smoother,
The car now drives much better and has increased power in 5th which is great for overtaking.
Well worth every cent

#278 mixmasterlooney

mixmasterlooney

    The Sexecutioner

  • FOC Supporters
  • 1,673 posts
  • Name: Kurt
  • Ford Model: Focus Zetec S
  • Year: 2010
  • Location: Greater London
Contributor

Posted 14 September 2013 - 04:54 PM

Update:
I've met the lads at MFK Auto Care this morning for DPF internal removal,
And I must say the guys done a very professional job the proof that dpf has been internally removed; can only be seen by the increase in smooth performance and increased MPG, fantastic job done and gives me great future peace of mind.

The guys took great care to ensure the chamber was weld back on along the original seal and all appears like it has never been touched, just like I had requested,

The results afterwards on the journey home were better than I imagined,
No smoke at all from the rear, not even when you floor it in 5th on the motorway, :)

There's a performance increase too,
If I was to describe the increase in performance it would be 3 times the increase in power felt from EGR blanking,

The engine ticks over at lower noise now
And the rev up is much smoother, increased air flow helps reduce turbo lag to almost extinct,
As result gear change is smoother too,
Its all positive, no more dpf no EML lights or fear of one appearing in the future neither.

And the guys were dead sound, didn't mind me watching and asking questions,
I highly recommend MFK Auto Care well worth making the journey and top class work very happy.
http://www.mfkautocare.com/

They also had a look at the ecu map I had previously put on the car and tweaked it a bit resulting in boost coming on smoother,
The car now drives much better and has increased power in 5th which is great for overtaking.
Well worth every cent

 

Pics lenny pics!! this sounds awesome! finding a guys in england who are willing to take such care in this mod is a problem for me



#279 mixmasterlooney

mixmasterlooney

    The Sexecutioner

  • FOC Supporters
  • 1,673 posts
  • Name: Kurt
  • Ford Model: Focus Zetec S
  • Year: 2010
  • Location: Greater London
Contributor

Posted 14 September 2013 - 04:56 PM

Oh yeah i forgot :- / you're no longer interested in the focus.. maybe i should start sending all my PM to vicky instead ;- ) that'll get you back on this forum lol



#280 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 14 September 2013 - 05:50 PM

 
Pics lenny pics!! this sounds awesome! finding a guys in england who are willing to take such care in this mod is a problem for me

It is kurt,
I had trouble fiding someone who would take the time to cut open the dpf chamber and remove the filter then seal it up like it never happend, all companys just wanted to remove the whole thing and fit a straight pipe,
Thankfully i found MFK Auto Care in meath who were more than happy to cut open the chamber as requested,
And made a fantastic job of welding it back up just like fords original weld.

Image2317.jpg

Here it is all removed except the catylist section,

IMG_20130913_153036_zpsa137f4d3.jpg

IMG_20130914_190240_zps17fe2ae3.jpg

If you're willing to travel over I can bring you to them,
Or if you put your car off the road for a week, send over the dpf and I'll bring it to be done then post it back to you
I've kept a bit of the dpf filter as a souvenir I'll post a picture,
Lots of needle sized holes
Here it is, imagine this mesh type ceramic 7-8" deep and the full circumpherence of the chamber,

IMG_20130914_190320_zps0337076e.jpg


I also had a look at the flexi-downpipe its already 2.5" diameter internally,
So the exhaust it now a 2.5" Cat back,
More grunt now too since it flows much better :)

  

Oh yeah i forgot :- / you're no longer interested in the focus.. maybe i should start sending all my PM to vicky instead ;- ) that'll get you back on this forum lol

:lol: pm vicki all you want mate,
Togeather 11 years now, she will be happy to have someone who listens,
No prob.

#281 VickiW

VickiW

    Too much time on the boards

  • True Ford Enthusiast
  • PipPipPipPip
  • 796 posts
  • Name: Victoria
  • Ford Model: focus st wannabe!!!
  • Year: 2010
  • Location: Ireland

Posted 14 September 2013 - 06:07 PM

haha...only one waffle in this house honey

#282 james132

james132

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 265 posts
  • Name: James
  • Ford Model: Fiesta Zetec S TDCi
  • Year: 2006
  • Location: Norfolk

Posted 16 September 2013 - 06:42 PM

Just popped back on the forum to have a look about and couldn't resist having a check up on your car.

Lots of fantastic changes and mods, the car is looking brilliant!

Keep up the good work pal!



#283 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 16 September 2013 - 07:35 PM

Just popped back on the forum to have a look about and couldn't resist having a check up on your car.
Lots of fantastic changes and mods, the car is looking brilliant!
Keep up the good work pal!

Thanks James mate,
Hope you are keeping well,
The focus is now complete, I may take on shaving the rear doors next year but other than that its done,

#284 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 23 September 2013 - 09:05 AM

Here's some videos guys,
I don't have an action cam , so I had to lye in the boot with my arm out holding a 7" tablet for this one lol
Vicki driving in both vids

th_VID_20130923_092155_zpsb00a8e8c.jpg

#285 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,690 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 23 September 2013 - 09:07 AM

th_VID_20130923_092316_zps297a067f.jpg

Have something to contribute?

Sign in or register to start a topic...


Not what you're looking for?

Register now, we have a huge community of enthusiasts to answer any questions you might have



0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users