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Discussion Starter · #1 ·
Work is being done by a company called KontrolFreakz in South Africa, this is a WIP thread, so come back often to see progress:

So, dropped the Driftmobile V2 off at KontrolFreakz for custom exhaust build. I will try and keep this thread going as a work in progress thread, so you guys can see it's not just a matter of slapping on a pipe.
Really LOTS of work need to be done:

Before all started


On the lift


Prepping started
Need to remove engine cover, lights, induction and water bottle.


Wiper removal
Need to removethe wipers and slide out the wiper blades

Remove induction:
Need to remove induction to get access to the top bolt on the DP.

Now, need to get past that heat shield so we can access the DP.

more to come .....
 

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Discussion Starter · #2 ·
Stock Down pipe and CAT

What a fugly thing!!



Stock CAT Back



Bye Bye Stock Exhaust



High Spec heat wrap


After a lengthy duscussion with PhillipI took his advice and asked him to heatwrap the DP, This high spec heat wrap.

 

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Discussion Starter · #3 · (Edited)
Turbo Flange cut and ready

This is for the new 76mm DP. Look at the workmanship, this guy doesn't rest. We are having issues over here to get new flanges CNC machined, will have to wait a couple of weeks, so we cut the flange off the stock DP.





 

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Discussion Starter · #5 ·
Reducing the 85mm turbo flange exit to 76mm






Welded on inside





Double welded on outside to prohibit cracking and breakage

 

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Discussion Starter · #8 ·
First lambda bung gets strategically placed

A 18mm hole gets drilled and bung welded into place.



 

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Discussion Starter · #9 ·
The experience comes in when you have to use pre-made Mandrel bends, where to cut them, how to cut them and at what angle to cut them, to make the system go
in the direction you want, whilst using as little as possible bends to optimize flow to increase performance.



When you grind through the steel, it ends up with a very ugly edge. Every single cut gets belt sanded and de-burred to get a smooth weld with nothing protruding
on the inside of the exhaust system.



 

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Discussion Starter · #10 ·
Stainless Steel high flow resonator gets prepped.

Double welded end pipes to make it easier to weld onto the system.







 

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Discussion Starter · #11 ·
A few bends, some welds, a downstream lambda and a resonator.

We are almost done with the down pipe. Phew!!!







 

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Discussion Starter · #12 ·
Now a flange to split the system.

We use V-band flanges as it also creates a seamless link.







 

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Discussion Starter · #14 ·
You then cut your hand, draw a Pentagram on the floor, light some candles...Witchcraft happens, and the whole system becomes shiny.







Now, lets wrap this baby for final fitment.





 

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Discussion Starter · #15 ·
Mini CAT fooler





Every single nut, bolt or sensor gets a dab of copper anti seize compound before they go back in.

 

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Discussion Starter · #16 ·
Final fitment in place

Now to put all the engine components back together, start up and check for leaks. Once it has a thumbs up, rear section can be started.





 
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