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-   -   Building a Harder, Better, Faster Chevy Spark | Includes Automech FFE Review (https://www.team-bhp.com/forum/modifications-accessories/138571-building-harder-better-faster-chevy-spark-includes-automech-ffe-review.html)

Umm, First of all Good ____ (fill the space here:) ) fellow BHPians . In the process of deviating M200 Chevrolet Spark from its stock nature, I’ve been doing some modifications – both cosmetic as well as performance oriented. I'd like to use this place to archive all the modifications which are onto my car over time. Thanks a lot for your support!

This thirst for modifying my can has come from 2 things:

• One, obviously TBHP especially the Tastefully Modified cars thread and
• Two, the Chevy USA lineup ::Corvette::Camaro::SS::

If you are unaware of my car, then you can go ahead learn about it here

Hopefully, after a couple of years I will have transformed my Spark into something unknown and unpredictable at this point of time. Once again, I'd like to thank everyone at TBHP for posting knowledgeable info on their cars, modifications etc.

So, let's roll
;)

In the performance regard, I’ve installed a K&N 57i kit last year which you *might* have come across in Long Term Ownership section.

FAQs

Why a performance filter?
A performance filter like K&N improves the volume of air breathed by your car. This simple video proves it,
http://www.youtube.com/watch?v=M9k781cdlm0

Do K&Ns make more noise?
In normal driving conditions no. But when you floor it, it is noticeable.

Do K&Ns mess with the MAF sensors?
Well, regarding this I've come across variety of answers. In my case, it's working fine. No issues at all.

Do K&Ns let in more dust particles than stock filters?
Well, I cannot comment on this. In my case, I've not experienced any issues with my engine performance like deteriorating etc.

This was the answer provided by them when asked if "K&Ns let in more dust"


I've quoted the review from my thread below:
Now, I've completed approximately 9K KMS using the filter. I'm definitely satisfied with the investment I've made.

Well, this time, I’ve taken the plunge and purchased a custom free flow exhaust from AUTOMECH Engineers, Mumbai. Before going straight into the review, let’s go through some FAQs below.
------------------------------------------------------------------------------------------------------------------------------------------
FAQs

Why FFE?
To help dispose of the exhaust gases from the combustion chamber as *efficiently* as possible thus reducing backpressure and improving engine performance.
This efficient disposal of exhaust gases is done by, headers which have smoother bends (greatly reducing air-exhaust wall friction). The plumbing used in FFE is generally of larger diameter, thus accommodating greater volume of exhaust gases.

What are the Advantages of FFE?
As said above, increases the *drivability* of you vehicle. In most of the cases, an FFE most also increase FE of you vehicle.

What are the disadvantages of FFE?
The main disadvantage is that a true FFE involves removal of CATCON (catalytic converter) which increases the pollution caused by your vehicle. The pollution increase doesn’t affect your car’s road worthiness since modern engines are direct injected (Vivek said me).

*Additionally an FFE leads to increased noise as there is less noise cancellation at the end can/muffler.
More here: http://en.wikipedia.org/wiki/Aftermarket_exhaust_parts

Once, this FFE fever struck me, I quickly started to acquire some knowledge on it through TBHP and other sites. Through positive reviews of many including our guru GTO and many others I’ve contacted Vivek Bhat of Automech. We had a really long conversation over Emails regarding the FFE.

Vivek Bhat, in a word is a really nice person to talk to, he definitely knows his work. The Automech team as a whole have been very responsive to my Emails, answering my every (some silly) query. I rate them 5 out of 5.

My requirements were,

• Noticeable improvements in drivability, especially, in Low & Mid RPMs.
• Stock silence at city driving, nice deep sound at the higher grounds-More on this later.
• A meaty exhaust tip. Yummy :P
• And importantly an all Stainless steel structure.

Vivek said that they can definitely do one and quoted a price of 14000 for the unit excluding 12.5% CST.
Overall, it was 15750 for an all SS FFE Kit.

Now the problem is Mumbai is 857kms away, and travelling down to Mumbai for getting 4 pipes is the last thing I wanted to do on earth. Thanks to logistics, I don’t need to go there. * smiles*.

The deposit was made in Automech’s Bank account, and Vivek promptly started his work. Within 4 days, he replied me it’s done and dispatched. And you know the eagerness of us BHPians. The next 3 days (as in the movie!) were intensely, ummm, you know, sleepless. Sleep deprived, I woke up one morning expecting the package. But naturally, due to god’s play(!) it was delivered @ 8PM night. Yawn.



First impressions? Oh my god, it’s freaking heavy(later when I held stock ones, they were even heavier). Who said FFE helps in weight reduction?!(Read it somewhere)I quickly grabbed a cutter, undressed the gleaming beauty(was packed in a gunny bag). Finally, I touched it. Yahoo!. I happened to, errr, kiss the headers which were sooo delicious. Quickly took some photos of every component in all possible angles, since I cannot do that once I get it fixed!Again it was sleepless as I had the raw materials in hand but no capacity to fix it myself. Next day, with a heavy heart I had to cancel the fitment as I had to attend my high school get together. :deadhorse



Ohh Yea, I forgot to say you. Who the hell is going to fix this for me? As we know this ain’t Maruti to have many workshops other than ASS. Also, the manifold (the stock one) was looking soo complicated; it’d be a nightmare the whole thing removed and get the FFE fixed. What if I end up with a broken stock manifold while I remove it? Getting back the stock components in their pristine condition was a concern of mine (they weren’t that screwed up to be thrown away). Then my situation suddenly was nothing short of Bradley Cooper’s in Hangover. I don’t have many contacts @ KUN Chevrolet (my local dealer). The Bradley Cooper state wasn’t long, I remembered Mr.Khalil (senior technician there). Met him explained him that I need help regarding exhaust. He smiled [may be that was because I was messing (in their point of view) so much with my car] have me an appointment the next day morning @ a work shop he knows.

Fast forward next morning; I was waiting for him in the car. He came, saw that the car’s rear seat was folded. He said, Ohh boy, that’s a complete exhaust kit! He he, although that’s what I’ve said him about yesterday he apparently thought I was talking only about the end can.
He said, it’s a big job (it is) and require more time. He said that he can do it comfortably without other work tensions (he works at Chevy, has come down to other workshop for me to spare an hour or so). I explained him my situation. I said him; I cannot have more sleepless nights. Finally, he agreed to get it done by the evening. Charged INR800/-

Before Fitment /First Look:
As I said before, the kit is quite heavy. The material and the build is *solid* which is very very apparent once you touch it. 95% of the body is Polished finish, except the (I don’t know what to call them) joints which are painted in silver. Next, ummm, the muffler tip is huge which I didn’t expect. Although there are pictures in their website, I didn’t happen to think it will be huge. That’s it.


The "things" which I suppose are not of Stainless Steel

Fit:
The FFE utilizes all the stock mounting locations, and fits precisely. Except for the muffler tip which touches the rear bumper. If you observe closely the Spark’s stock end can looks a little weird with end can right behind the bumper, but the tailpipe comes from the other end of the end can. This is, errr, quite hard to explain! Therefore the pipe is little towards the center of the bumper, on the inner side I mean. But this FFE doesn’t use the *cut* in the bumper which the stock one has. Pheww, let the pictures speak. This is hard.

After Fitment:
After fitment, my knees were shivering whether it’d work fine/ not. I was told to switch the vehicle on, to check for leaks. Remember, the vehicle was in a 3 way enclosed (by walls) workshop. Brrrrrrrrr - pur pur pur(pop sound) – Brrrrr - pur pur – Brrrrr. There you go, my Spark got a notch higher, and the whole place tasted a new sound. After a preliminary check for leaks, we went for a test ride. I was driving, and once I leave behind the “civilized” driving, *all the hell breaks loose*! Regarding the sound, there is a constant bass you hear on the inside (when music off) and outside (always).

Okay, let us keep sound out of the equation. Once, I switched the car on – Makkan Yaar! – The car made it official that it’s breathing much healthily. Vivek’s cast a spell on the car! Once I hit the road, the car is much eager to move. Suddenly the car felt as if it was riding on – Low rolling resistance tires, fully synthetic oil, and blah blah – simply put *less friction everywhere*. The car felt as if it recovered from 6 years of *cold and other breathing issues*.

Now on the performance front, yes FFEs tend to improve the drivability and FE. Definitely, Yes. In my case, the car has transformed completely into a different animal. The power band has definitely shifted into lower rpms. If you are a Spark owner, you realize you have to wait patiently for the power to build up once you pass a pothole/speed breaker. Well, that is really annoying especially in 2nd gear. Now the car says I’m available anytime, anywhere.

Now, I stated that the FFE was optimized for Low/Mid range improvements. Heck, if I had a tacho I’ll have explained it better. Previously my car would top up at 90 or so. But on a recent trip it dared to go obtuse. 117kph for the first time, very comfortably. Athletic, agile, handsome, robust and more so ever sweet car it has become.

The other day I had to perform an overtaking maneuver in 3rd and I was too busy to shift to 4th. Yet, the power delivery would not terminate even at high rpm. I loved it. I’m sure; the car is now able to handle higher rpms at ease. Also I need not change gears frequently, it picks up in a higher gear without the knocking/jerking issues.

Regarding sound, the car is stock silent but there is a constant bass you hear when idle as well as you drive. The sound delivery is so sophisticated and happens in stages, *artistically/beautifully* building up, in every gear. The sound is all harmony at lower gears. All the *substance* is from the mid range where the sound transforms into a wilder note. Let me say, there is a *sharp tapering effect*at the muffler end at mid/high rpms.

The FE has definitely improved. I’ve recently done a 350KM trip and the petrol expenditure was about INR1300 or so, which by my regular standards is very less.

In the following pictures, the top picture is of stock one, the bottom one is AM FFE.


Stock Manifold inlets vs AM FFE Header Inlets


Stock Manifold inlets vs AM FFE Header Inlets(Closer Look)


Stock Manifold inlets vs AM FFE Header Outlets


CATCON in Stock Exhaust & next component in the FFE Kit (Not to Scale)

Other Pictures:


RHS View of Headers, O2 Sensor at the Right


Closeup of O2 Sensor


Closeup of welds


The copper piece to prevent leakage @ 4 to 2 joint (I mean 4*2 joint)


Man!!! Catcons are very busy busy(nevertheless they do a very good job)


Stock End can

A very happy engine


I love that roasted color!


She herself gave a pose, I didn't even ask her to dress up like that. May be the FFE Effect! lol:

Thanks to Vivek and his team, each and everyone @ automech who worked on my FFE. Thanks!, I’m so satisfied. I’d recommend Automech to any car owner who has a thing regarding his car.

Man, from the pics it looks like the exhaust ports on the head are square, but its not a problem if the round header flange entries cover the square ports. However in the photos it looks like (based on the OEM manifold entry size) the round header entries are significantly smaller than the ports. That is not ideal.

Nice report & super pictures.

I'm loyal to Automech. Love the sound & bump up in performance their exhausts provide. Plus, my Vtec & Civic never had to revisit the shop for so much as a loose bolt! The install is absolutely perfect.

Suggest you verify & take corrective action as per Sankar's post though.

Very nice mods Eminenttismo!:thumbs up Certainly would give it a detailed read but of course, with the increase in pollution, the road worthiness of the car is affected. Without the CatCon, there will be emission of dangerous gases in the environment, and the car will fail the PUC check!:)
Agreed that there might not be any deterioration in driveability of the car.

Regards,
Saket

Thanks a lot man! I felt something fishy while joining that pictures, but I was in some "nasha" of the performance boost. I've put up a mail to Vivek Bhat regarding this. Hope he clarifies.:thumbs up

By the way, what if the outlet on the engine cast is circular? I hope it is!


+1
Thanks a lot! I've put up a mail to Vivek, expecting a reply by tomorrow. Will update then.

He he! Thanks! Yea, I can feel that the pollution has increased. The car smells bad, I mean the smoke.


@ GTO, can you please clarify, did your car pass PUC test? :Frustrati

Got a reply from automech:

How is the size of the pipe determined? Sankar can you please help?


Thanks!

Well, I asked Mr.VivekBhat on how the diameter is calculated and he said they have a formula(which he apparently cannot share) depending on Engine Displacement.

So far, the vehicle has been so good. I'm enjoying the ride. :thumbs up