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Lenny

"taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

1,412 posts in this topic

Thanks Lenny

I will have to have a think about it..

Time is an issue for me I don't seem to have much of it lol!!

But I would love them yes!

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Small update,

Came home from night shift at 07:30 and removed the air box lid,

Cleaned the flys off and began marking up the front section of the lid then i drilled six 20mm holes in the front right side of the Air box lid to help induction, bored out the top three holes to form a scoop shape.

Took it for a run afterwards, induction noise has increased and pick up seems a bit smoother when crushing in 5th gear and put the foot down seems smoother on pick up.

IMG_20130816_120126_zps4918ce52.jpg

IMG_20130816_120222_zps8f447eb5.jpg

IMG_20130816_120240_zps02be156c.jpg

IMG_20130816_120154_zps114c3396.jpg

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Great build thread dude. Nice work.

Thanks mate, your build with the Mondeo is lookin sweet,

Very nice job on the headlights too.

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Cool idea Lenny. Maybe a video clip to get an idea of the sound with the holes in the air box please? Thanks

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Thanks mate, your build with the Mondeo is lookin sweet,

Very nice job on the headlights too.

They were a total pig to do!! Thanks for the compliments.
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Cool idea Lenny. Maybe a video clip to get an idea of the sound with the holes in the air box please? Thanks

I'll see what I can do mate,

Need help from Vicki's right foot for a few minutes lol if she has one,

Never bother to look at her feet to be honest ;)

Let you hear the exhaust too meant to do that before now,

They were a total pig to do!! Thanks for the compliments.

I can imagine they were mate, I've got a set of chrome focus headlights, I'm now selling them,

I had thought of trying to remove the parts and colour code them prior to selling but so much could go wrong in the processes

I'm just selling them as they are untouched.

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I reckon Vicki would kindly oblige all in the name of science and to get you to stop talking about it :P

That airbox mod looks like it could be very beneficial for smoothing out the response if more air is being delivered to the engine.

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I reckon Vicki would kindly oblige all in the name of science and to get you to stop talking about it :P

That airbox mod looks like it could be very beneficial for smoothing out the response if more air is being delivered to the engine.

I reckon Vicki would love to kick his cars puddings in, in the name of science as you stated ;)

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I reckon Vicki would kindly oblige all in the name of science and to get you to stop talking about it :P

That airbox mod looks like it could be very beneficial for smoothing out the response if more air is being delivered to the engine.

Give me a few days and ill try get a video up,

Dont really want to redline it in the driveway lol neighbours wouldn be best pleased

I reckon Vicki would love to kick his cars puddings in, in the name of science as you stated ;)

Please don't lol it's like when you say beetle juice three times George, ive gotten her off my build thread, hoping to keep it that way lol

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Ball juice ball juice ball juice ... victoria is busy looking after her 3kids including lenny...id be more than happy too put my foot down on leos balls and video it ; )

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Give me a few days and ill try get a video up,

Dont really want to redline it in the driveway lol neighbours wouldn be best pleased

Please don't lol it's like when you say beetle juice three times George, ive gotten her off my build thread, hoping to keep it that way lol

Sorry Lenny its more fun for us when Vicki has input lol

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Update:

I've found a company in Ireland that has agreed to remove the DPF internals and return the empty chamber with all sensors and pipes connected, so it looks like its never been touched.

They will then remove the DPF files from the ECU and reduce the emissions to ensure MOT compliant.

All this for 395 bargain!

I've booked a day holidays for early September to take the focus and have it done,

I'll update with pictures as it happens aswell as inform others of the company name etc. When complete

I will also enquire about getting the "flexi down pipe" replaced with a stainless 2.5" diameter instead of the stock 1.5" as saw below

KGrHqFHJDkE9BB-Er9BPWIWCKJg60_58_zps1574

KGrHqZioE6-eTmqTBO3iBbEw60_58_zps2678f52

If the "flexi down pipe" was 2.5" it would allow the waste gasses to flow better as the piper exhaust attached to the flexi is also 2.5" and the pipe leading from the DPF chamber also seems to be either 2" or 2.5" as you can see in the image below,

DPF - down pipe - flexi down pipe - 2.5" straight - back box - tip

The closer you get 2.5" to the manifold the better it is for performance.

Image2317.jpg

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Update:

I've found a company in Ireland that has agreed to remove the DPF internals and return the empty chamber with all sensors and pipes connected, so it looks like its never been touched.

They will then remove the DPF files from the ECU and reduce the emissions to ensure MOT compliant.

All this for 395 bargain!

I've booked a day holidays for early September to take the focus and have it done,

395 bargain???

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395 bargain???

To have the DPF taken out, internals removed and refitted to look like it was never removed is a compete bargain,

Save fuel, eloys fluid, and the cost of replacing the dpf at some point, combined saving of over 700 in the next two years.

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395 bargain???

Vicki, its not a bad price when it includes the software delete too, I know over here when you get a remap they will do this dpf delete at the same time in with the price but when you put it into perspective Vicki its only the price of a decent handbag :P

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Vicki, its not a bad price when it includes the software delete too, I know over here when you get a remap they will do this dpf delete at the same time in with the price but when you put it into perspective Vicki its only the price of a decent handbag :P

George id rather pennys (primark) hand bag with 390 cash in it for ford fair next year to see all ye owl lads!!!!lol

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George id rather pennys (primark) hand bag with 390 cash in it for ford fair next year to see all ye owl lads!!!!lol

That sounds a better Deal Lenny , no one will see your exhaust , but if you go to the Fair , then we will all see you two :)

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That sounds a better Deal Lenny , no one will see your exhaust , but if you go to the Fair , then we will all see you two :)

I thought we was friends Paul...

Your supposed to side with me lol

I'll be at ford fair next year plenty of time to recover 395 and still purchase the hand bag For F#$% sake

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I thought we was friends Paul...

Your supposed to side with me lol

I'll be at ford fair next year plenty of time to recover 395 and still purchase the hand bag For F#$% sake

Lmao Lenny , do they do a Ford handbag ?

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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.

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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

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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

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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

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