I have just finished cleaning the inlet manifold and injector manifold for my Zetec conversion and am rather appalled at the poor port matching. I am using the 1.8 zetec Escort inlet manifolds as part of my 2.0ltr Zetec conversion on the Escort.

The problem is largely with the injector manifold. where it mates with the inlet manifold tract, it is flared and so becomes larger than the inlet manifolds tracts.

I had a similar problem with the original engines manifolds (1.6 CVH MFi) and simply flared the manifolds ports to match. However, this creates a large 'pocket' in the inlet tract which will no doubt upset the air flow and the final engine performance was a bit dissapointing.

The only other option I can see it to fill the flared portion in and regrind to match the inlet manifolds tracts. However, I am now a bit concerned as to how well any filler (proper alluminium filler/chemical metal) will bond to the manifold and stay put. I doubt the cylinder head will thank me for injesting bits of filler.

Does anyone know of anything available that would fit the bill? I have thought of alluminium welding but was hoping to avoid that as there are still issues with bonding (cheap ally castings) and getting the face reground to get it flat again.

Or is there any other sollution?(I know that sticking bits of filler in the inlet tract seems a bit cowboy like but how else can I overcome this step?)

Would I be best to just leav it as it is?

What do you tunning boys do?

Any help would be greatfully received.

Cheers,
Smiler.