Kermit Modifications

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hilst I’m sure the boys in uk·rec·cars·modifications (see Usenet) would like to read that I’m contemplating dropping in a turbocharged 2·0 litre Zetec unit, courtesy of Severn Motorsport, my plans for the Ka are rather more modest.

Before you read through this page, I’d recommend you take a look at Kermit’s Theme, and the reasons for our modification direction.

However, some people are quite happy to modify their Ka, and below are some of the things that can be done to the Ka, of which I’m vaguely considering!

Better Breathing: most people consider the standard Ka induction system to be rather restrictive (there are pictures of the standard Ford set up here). Ford Motorsport offer a higher performance induction kit, which is reputed to give a small power increase (which can translate into either a more efficient engine, for better economy, or more power, for better performance), but I’ll be a Nova driver if I can find a dealership that sells the kit! There are some problems associated with the fitting of an induction kit, such as K & N’s popular 57i. The main problems are associated with cold weather, which can cause poor running. With this in mind, I have instead opted for a replacement high performance panel filter and I’m working on a custom induction system.

More Intelligence: Ford Motorsport offered a modified ECU for the Ka, but we’ve gone down the route of the Superchips Bluefin device. However, Superchips certainly do, and all in the cost would be around £225 (including the discount that the Ka Klub offers). The modifications will increase the power slightly (again, which gives either better performance or better economy). You can read about ECU upgrades here.

Spunkier Headlights: there’s nothing wrong with the Ka’s dipped headlight pattern, or for that matter with the main beam. But it can be improved, and we’ve done so using the Morette triple headlamp conversion.

Bad Weather Visibility: there are two options if you want integrated front fog lamps on the Ka: the MS Designs lower spoiler, or the Orciari option, which is the one I’ve gone for. If you’re that way inclined, you can squeeze the lamps in yourself, as illustrated.

Surer Anchors: if I’m going to use Kermit on track days, his braking system will probably need shoring up. The ventilated front disc / rear drum system works very well on the road, but it’s possible to get brake fade if you try hard enough – however you have to be driving like a loon for this to happen! There’s also four channel ABS, too.

Superior exhaust: in fairness, this is more associated with the noise improvement than any power gains, primarily because without removing the catalytic converter, fitting a bigger exhaust does nothing for power output. It can even reduce power – if you reduce back pressure without any other modifications, you’re likely to reduce overall output. Have a read about the lad’s new back box, which we then replaced with the PowerFlow cat-back system. We may also replace the manifold for a faster-flowing system.

Camshaft re-profiling. This involves taking a few thou off the base circle of the cam lobe, meaning that when the slack is taken up, the sharper end sticks the valve further into the cylinder - hence more lift, more gas into the engine, and more power out. Although you can get rather extreme profile replacement camshafts, I would prefer changing the profile to something only slightly more aggressive than the standard cam, but not so much as to reduce driveability lower down in the rev band.

A bigger beak of sorts: we tried Kermit with the MS Designs Grill Surround, but after about a year we took it off. Instead, we’re getting a special custom made grill with “Kermit” in the middle, especially for the lad!

More downforce: hardly! Although the Ford spoiler looks rather nice on the Ka, it is quite expensive. More importantly, there are alternatives – some bigger than others! We went for the Orciari rear spoiler, which is one of the more subtle ones.

Warning lights: I love the simplicity of the Ka’s dashboard, and I don’t want to add any additional dials (even if a vent-mounted rev counter has appeal). However, part of me would still like some notification that the engine is getting warm. Unfortunately, plans to design a little box of tricks with LEDs to show that the engine was cold, the cooling fan was running, the coolant temperature was hot, and the external air temperature was below five degrees have been shelved because of the complexity and cost involved in the various sensors. Instead, a much more simple LED showing that the cooling fan is running is a very inexpensive alternative. How useful this will be is still open to discussion.

Cosmetic Nip & Tuck: I like the design of the Ka. In some respects, it is beautifully simplistic and yet in others, the first time you see it, you wonder quite how Ford have made it so curvaceous. However, there are a couple of little modifications I am considering. One is the universal coloured side indicator repeaters - they’re orange as standard, I’ve had them replaced with smoked side repeaters. Another is to get the door handles and locks sprayed green, plus using mesh on the front indicators and those fantastic lightbrows! The rear lights have been replaced, and one is to remove the B pillar strips.

Cruise Control: Cruise control is a bit like marmite: you either love it, or you hate it, or you’ve never tried it. A cruise control system really comes into its own on a long drive of several hundred miles, since it allows the driver to relax his or her right foot. I’m certainly interested in a cruise control system for the Ka. I would be happy with just a simple system. It just needs to maintain a given speed - it is no bother having to reset the speed because of traffic conditions, or similar - it will make the Ka much more comfortable to drive a long distance! You can read more about Cruise Control Systems here.

Hot Air: You’d not think that I’ve put a bit more effort into researching this aspect of things: check it out here.

Turbocharging: an interim discussion on turbocharging the Ka is here.

Custom Instrumentation is provided by the OBD-II Scanner and Palm m130 set up.