i build the area six style over the gearbox type so i would say mine haha, but to be honest mate i would say the obx as its very cheap and with 300bhp running through it i did think there would be any issues , however if you want more room and heat soak away from the engine and radiator and want to mount the turbo over the gearbox the i would say the area six style cone design . here a pic of my engine but it was the first manifold i built and things have move on a little since then in terms of design etc



hope this helps

 

oli at nms still uses standard cvh exhaust manifold on his barmy s1 which at full whack is over 400bhp.

 

thats good going by why would anyone want to put on a zetec ?
ps i have done it for a friend and most of the holes you need to drill into the head go into oil and water ways and some into really thin parts of the head, there really is no point in doing it when you can get zetec tubular manifolds off the shelf or the standard cast focus rs one

 

if he wants to build it cheaply its an option witch has proven it has a high enough flow rate for 300bhp?

 

ive heard that its not standard , its been ported etc not exactly sure but yes i used erst manifold on my first engine running 300 bhp never had any probs. on a budget its fine but when running serious bhp then theres more to think about than just what it flows , like engine bay temps , rad temps , heat soak , room in the engine bay etc , but yes very good standard manifold

 

yeah totaly agree with what your saying paul but as he was on about a budget build so was i

 

yeh mate i think theres no such thing as budgets and iam sure the missus would agree cause fook , my ears have been bleeding since i started my project

 

haha yes but can i say yours is by no means a budget build

 

Ł10500 worth of zetec mate soooooooo no i wouldnt say it was a budget build , and its still not finished , got the inlet to buy , 4 more injectors , dry sump system , another cam , head bolt mods to the block and another run on the dyno yeh!, probably end in disaster

 

so your looking at probz another 3-4ish grand for engine and the shell your creating isnt a present either mate lol.as im kind of only down the road from you i cant wait to see it in the road.

 

yeh mate well will meet up one night , do you go to thre rsoc meet at the paddock , never been myself but my mate lives 2 doors down and he always saying to go , fookin rs 1800 fiesta cost me more than my new car and its just failed mot

 

yeah defo mate be good that.well when i said i live just down the road i ment like alfreton/matlock way so about 20-30mins.no never been mate as i havnt got my fiesta on the road yet STILL as im young and earn really rubbish money.oh deer i never seem to have any look with fiesta's but cant stop buying them lol.

 

if you use any type of tubular manifold then you WILL need a turbo brace/hangar or it WILL crack!

doesnt matter if its a Ł2k HKS one of a Ł100 XS power effort.

imo if your on a budget, go for the RS turbo manifold

this is mine, not quite finished yet tho.

 

yeh totally agree mate especially over gearbox type , god zetecs look good that way round , cant wait to see mine at this stage , looking good mate

 

cheers bud, most of the wiring is done now, so hopefully not far off turning the key.

or pushing the button as their isnt a key lol

 

good to hear it mate been following this from the start in the mags , hope the zetec shows the cossie boys a thing or too.

 

i just hope it doesnt blow up lol

 

ive been running mine for four years with no brace or hanger and its never cracked but you defo would on the over the gearbox type.

 

what manifold is yours mate?

sounds like you have been very lucky then. i have known of of very expensive hks items to crack and fail due to no brace, mine is an xs power 200sx one, and its got a brace lol

 

hey you boys are close to me i am a staffs lad go matlock to see this bikes use ride up but now no bike

 

they were japspeed manifolds and not lucky i have made four of them two on escorts and two on fiestas none of them have ever cracked.

 

what turbo are you using? mine is a bit smaller than a T4 and weighs a ton!

fair enough if they havnt cracked yet

 

mine runs a gt28,one runs a stg3 t3 and the other two both run t34s

 

is area six still open as looked around and there site says they cloesed now :S and also would i be best going for cvh manifold then or ther obx dont seem bad for the price as aint after mega power so hopfully wont crack

 

no area six is closed , off the shelf parts are avaible like pistons and rods etc , no engine builds and no exhaust manifolds but they are avaible through me , i would use the cvh as its very cheap and like i said it was perfect for 300bhp , the only down side is you have to drill and tap the head but wouldnt cost you anymore than Ł50

 

so drill and tap best way? rather than the adpotor plates you can get? think im just going look for a 2.0 head then and get it drilled and tapped and have some work dun on it then take the 1.8 quick rebuild mate the new head up and boost boost boost

 

build yourself a full 2.1 litre zetec turbo , fitted a 2.0 litre head on a 1.8 bottom end does not make sense as compression ratio , valve clearance will be changed , carry on driving your car and just buy a spare engine for Ł100 and build it at your lesuire .

 

well just won my self a 1.8 gti head of a escort so just going keep the hole thing bassed 1.8 as aint after big power with this engine just summit nice and easy get me into engine building and the fun of having a turbo untill i move onto summit jap in a few years

 

you can still get a good 280bhp mate out of the 1.8 as i said before pistons and rods are the key this is the spec i would go for
i take it the engines the silver top version?

engine

eagle rods Ł700
forged pistons Ł700
new genuine fiesta rs1800 oil pump Ł80
new geniune fiesta water pump Ł60
all new gaskets Ł50
new shells etc Ł100
standard crank Ł n/a
block drilled and tapped for extra engine breather ports Ł30
fiesta 1.8 sump modified for oil returns Ł20
hone and decked block Ł50 to Ł100
new multi layer headgasket Ł40
orginal front breather blocked Ł10
new cam belt kit Ł50
standard cylinder head with uprated valve springs Ł300
head drilled and tapped for cvh exhaust manifold Ł50
fiesta rs 1800 / 2.0 litre cams Ł30 to Ł50
fiesta rs 1800 inlet manifold / fuel rail / throttle Ł100
uprated fuel injectors Ł250
aeromotive uprated fuel pressure regulator Ł80
cvh flywheel modified to fit zetec crank Ł40 (ive got a spare one)
new head bolts Ł20
all new sump , water pump , oil pump , flywheel , cam cover etc bolts Ł20
secondhand thermostat housing Ł n/a
t34 turbo Ł750 (new)
oil pipe feed for turbo Ł20
focus rs plugs Ł30
new leads Ł30
secondhand coil pack Łn/a
bailey oil breather tank Ł120
custom boost crossover hose Ł120 (ive got one spare)
and most importantly a decent management system
i would say pectel t2 ecu Ł650
custom wiring harness Ł450 (send me a pm about these two)

thats the engine sorted

also

uprated alloy radiator Ł300
uprated pro alloy large front mounted intercooler Ł450
stainless cosworth large air filter Ł120
silicon bends Ł250
stainless boost pipes Ł100
amal valve Ł40 (ive got a spare one)
and a live map Ł250 (ahmed bajoo highly recommended)

that should see a genuine 280/300 bhp @ 20 psi

hope this helps in more detail, but all prices are a rough guess and could be less that ive quoted

cheers paul

 

if you want to keep it a 1.8 then its going to have to be custom pistons, standard off the shelf pistons for a 2.0 will take a 1.8 to a yep, you guessed it. 2.0. Also, not wanting to tread on your feet paul, but a set of eagle rods imported from the states are a lot cheaper than Ł700, also AFAIK the 1.8 and 2.0 head have exactly the same castings and it would be much better to weld a zetec flange on to a ERST manifold. Good luck with this mate, just accept its not going to be a cheap and quick build

 

i can get eagle rods and forged piston to your door for Ł600 for all zetecs zvh cvh ect

 

cheers guys for all the help just cant wait to get some funds and get stuck in on it

ps paul its a escort gti head so thinks its either a phase two siliver top or a a black top

now then for the inlet side whichs will be my best route a custome job vey expensive really or going for the standerd focus rs which should be a str8 fit or going for the efi? i belive of the older cvhs the one were it sits slight over the head and have the pipe running across the head which would line up nice with the rs escort manifold also found a company that use the 2wd cosworth inlet as well so whats going to be the best style of inlet for the power i wish to run?

been looking into the obx exhaust manifolds tho they are cheap and with a bracket for the turbo and only running small boost as i have now set my eyes on 200-220 max bhp as i would like to build this engine up then mayb build an 2.1 for a kit car or sumthink along them lines do you guys think they would take the boost or would crack? or is the escort still my best option here but does drilling and tapping the head weaken any part of it?

cheers again guys slowy starting to get my head round this god ford engines are cool wehn i was over witht he clios there is not a lot you could do unless you wanted to spend Ł3-5k

 

bump

 

it will cost you 3-5k to build a good zetec turbo and if you cut corners it will cost you more in the long run to do it twice

 

as i said mate sort the bottom end and then mod it as you want , if you want a budget build which it sounds like then try and use as many second hand tried and tested parts . rs 1800 inlet manifold and bits , erst manifold
i can help you out with some parts which are left over from my first build
(pm me if your interested)
parts are
cvh flywheel modified to fit zetec crank
stainless steel over cam cover boost pipe
amal valve
area six spec bailey motorsport oil breather with jic fittings
area six metal oil breather pipes from the back of the block to the oil breather
erst cvh manifold

cheers paul

 

hey mate pm me some prices on some of the bits you got as you only in derby aint to far away am am in stafford/stoke on trent

so rite the spec i was thinking on a budget would be

1.8 bottom with new bearings and shells
arp conroad bolts and balalend con rods
1.8 pistons and use a de-comp plate for comprasion
the head i got skimmed and mayb a touch of head work
rs 1800 cams or after market
rs 1800 inlet or efi inlet off erst
erst manifold drill and tapped intwo new head or possibly obx or save up and get a decent one made up of ya self etc so can transfers it over two a 2.1 build
thinking of either mxt75 box or the st170 for the 6 speed
front mont intercooler
oil cooler
megasquirt managent


this is what can think of top of me head what do you think as basic spec to aim for?

also could you let me into what a wastegate is as seen you need one but not no to much about turbo cars and learing the ropes is a wastegate what people replace with dump valve etc? cheers for all ya info mate you are helping me alot

 

god when i posted this i new nothing about car's or had any idea how to turbo them, but am now in the process of doing this for real on my own car.

i am using a 2.0 blacktop engine

going back thought the list of manifolds i want to give the 200sx one ago what's involved in this? buying a 200sx manifold like so..
http://cgi.ebay.co.uk/NISSAN-200SX-S...1#ht_528wt_905

then cutting the flange off and welding a zetec flange on? do all the primary's line up or is adjustment needed?

cheers guys leigh

 

none of them line up .

 

How hard is it to adjust them mate?

 

to the top really wanna no how to mod the 200sx manifold as in the position to buy one one firday