Just drove a few miles, looks like the exhaust mod worked. No more strange smell in the car, ran from 0 to 45 miles an hour for a while with the windows slightly open and the air stayed fresh.
Now i want to make a nice one, this one looks like the hunchback of the Notre Dame. I might have to cut a little out of the bumper but we'll see if i can make a nice looking one that also works good.
Makes you wonder, before the cat removal i didn't smell anything but nothing changed but the exhaust. Meaning that although you didn't smell it, exhaust fumes were entering the car without you knowing it. Not very healthy and i don't think very safe to.
I know my Benz had 2 dedicated holes in the sides of the trunk with springloaded flaps. Especially to let air escape out of the car but don't let air in other than through the designated vents in front.
I know that with the Ford air is coming out of the holes where you place the jack, felt it blowing when laying underneath the car. So there will be holes or slitts underneath the trunk letting air (thus exhaust fumes too) in too, otherwise you wouldn't smell the fumes.
Said it before but the build quality in comparison to the Benz is almost terrible, the feel, the way things are constructed and assembled on the Ford (even though the Benz is 27 years old) is no match. Even the plastic things on the Benz don't break after 27 years of service, with the ford i already have several plugs were the locking simply broke off just touching it. Also paint quality, on the Ford the paint is so thin, in comparison the Benz paint is much sturdier and chip resistant. Of course the Benz paint wasn't waterbased in that time.
Enough whining, overall the Ford is a nice car and i have a lot of fun driving and modifying it. It's no comparison cause the Mercedes W124 was the best Benz made ever in terms of driving and build quality. After that the quality dropped dramatically.
Think i will be going to the scrapyard next week, i just want a good cold air intake, keeps bugging me and i want it to be right.
Also found an old vacuumcleaner hose, If i can't find anything good next week i'll make an extra cold air intake from underneath the bumper behind the grill to the air intake.
Also thinking of putting a heatshield beneath the airfilter box and around the U turn pipe connected directly to the airfilterbox. That should also help keeping a little heat out of the fresh air. But only if i can't find a suiting replacement airfilterbox.
Also thinking of putting in extra sound isolation but that will take a while, i think they should have put in more (or better) isolation behind the dashboard. The engine is very noticable when accelerating and i would like that to be a lot less. When on speed it's quiet enough although the tires make a lot of noise. And i think you can also hear the left rear bearing so when i change that there should also be less noise when driving.
Maybe a full matt underneath the hood will also help.
Also wonder why Ford didn't put a cover underneath the enginecompartment, would protect the engine, reduce noise and increase milage because of the better airflow. Read the new Fiesta's have them but they will probably don't fit the Fusion.