I am building a Rover inlet for my zetec blacktop at the moment.

The standard focus mk1 fuel rail, fuel pressure regulator, and injectors are a straight fit. I needed to cut a little of the manifold where the fuel pressure regulator was sitting to line up the injectors properly. You need to fix two small brackets to secure the fuel rail to the manifold.

now I am at the point where I need to fit a throttle body and ICSV. I will use a Focus/Mondeo/Escort ICSV with an adapter plate welded onto the TB.

The standard focus TB , and Mondeo one's, have got the air bypass section. If I TIG weld an adapter plate onto the manifold and bolt the TB on it, I cannot use this air bypass hole because it is blocked. (opening it up is not an option because the hole will sit outside the manifold's intake pipe. People say that the Fiesta Turbo one can be used. They are rare in the Netherlands, so that is not an option ATM.



My questions to solve this problem are:

1. If I am running a vacuum hose from the manifold to the inlet traject (bypass the TB), I would create the same situation as when the air bypass hole in the TB is working, right? I guess it is just to bypass the butterfly valve.

2. The air bypass 'intake' hole is above the butterfly valve in the TB. If I drill a hole underneath the butterfly valve I have created myself an air bypass as well.

What is your opinion about this?