Lee read

hi guys I'm going to have a bash at making my own inlet. Iv got an idea of how I want it to look. So I'm hoping for a similar one to the one in the picture obviously 4 cylinder not 6 so will be a little smaller. Now I want some help. Ie what i will need, injector position and anything else I might need to add.

stevieturbo

Lots of talent, aluminium welder, tools...etc etc.

Retain OEM injector position and angle where possible, they've already done the hard work.

This place sells some random component parts.

But really..if you can buy one that is already a close match for your car or port spacing, doing that and adapting might be a lot easier.

http://www.rossmachineracing.com/index.htm

big_wasa

With a Zetec I am a fan of chopping of the runners and using the sandwich plate to hold the factory fuel rail ect. It should act as a thermal spacer.

Its then just a plate, runners, trumpets and plenum.

big_wasa

The Misti Evo 3~7 is a fairly good port match to the Zetec. The Evo runners are bigger. But with an adapter plate you can have the look your after with little fab.

big_wasa

Notice I say look and not flow or quality.

Lee read

Do you not think it will flow well or something. I thought that design as it would flow quite well. And that evo manifold looks fairly close to what I want. How well do they flow??

stevieturbo

If you couldnt make 4 figures on any intake like that...something is badly wrong.

big_wasa

I’ve cut one up to make it rwd but I havnt had it on a flow bench. It’s the only real way you would know.
But having cut one up I suspect it would split before it out flowed the standard manifold as used on a Focus Rs.
it is a chinese special after all. It does have descent trumpets.

I sold it on a few weeks ago in a clear out.

big_wasa

Lee read

That's a Chinese special? It does look quite good for one if it is. What thickness is the ally?

Turbo Zetec

iTrader: (1)

I've got an evo manifold fitted to my zetec turbo in my sierra. The ports are huge compared to the zetec and if i did it again, i'd probably sleeve it down at the trumpet end rather than doing a short blend at the head end.



It's not pretty in my engine bay, but it's functional

visa_broke

Sapphire or sierra, anymore pictures?

big_wasa

I would be interested in what boost you putting through it ?

The plenum is pressed from a 2.5mm sheet and not cast. The short bit around the neck is welded together.
The runners and trumpets are substantial.

Its the old trade off price over quality. The quality parts Stevie has linked to is going to add upto a Ł750~ manifold. The chinese Evo plenum was 15% of this.

This is mine in mock up. It’s in steel as I am still very new to welding alloy.

zetaboostboy522bhp

Cheap way

use fiesta turbo cvh lower manifold and fabricate the box etc and use the fiesta turbo fuel rail and throttle body , should be good for 280 bhp

Use a fiesta rs 1800 /escort high output zetec inlet manifold , fuel rail will limit you to what power you want as side feed injectors are limited , up to 400/500cc which for most is plenty unless you chasing big numbers. Also depending on which management your running will depend on things , I ran fiesta turbo ofab management so welded the idle control valve hole up and had a plate fabricated to fit a fiesta turbo throttle body so run the idle through the adjustment screw , it worked very well on my zetec turbo and when live mapped by Ahmed bayjoo (rip) it was fantastic and running a genuine solid 280/300 bhp.

now the more expensive way but proper imo

use the jenvey zetec inlet manifold around Ł250 which use can have the injector pockets machined in , fully o ringed for better sealing. Then use some ally tube to extend the runners to suit your application (zetec loves longer runners 8 inch for high powered big big torque as used on will gallops rallycross engine) and weld them to the inlet manifold and used the jenvey cast 19mm air horns around Ł20 each and weld them into the box section of the inlet before welding the lid on. Lots of injector choice , very robust and proven to flow over 500 bhp if you build the correct box inlet. Some people use alloy fire extinguisher bottles and use that for the inlet section. Use at least 5mm thick plate as I've seen thinner blow apart and don't grind the welded down unless you know you've got good penetration.

hopw this helps

cheers paul

big_wasa

I would agree the jenvey sf is the best off the shelf direct to head start you will buy. I think I priced it at getting on for Ł350 machined and delivered + vat ect.

The only way I would entertain the Ho Rs/Xr manifold is by machining the sandwich plate to take standard end fed injectors. Can you get new fuel rail seals for the side feds ? I couldn’t find them ten years ago and the old ones struggled with vacuume let alone boost.

Its all down to the power you want, the cash you have to spend and your ability to make stuff and packaging. I only want 225~275 so I can compromise to make it fit.

Lee read

Thanks Paul that it a great help. I want to go for the 500 mark. I will take close not of what you've put and see about Collecting parts

Lee read

are those the parts Paul?

big_wasa

From memory the 40’s are a nearer match dia wise unless you can tapper the runners.

This guys work is worth a look for some ideas.

Zewspeed

I can’t get the link to load.

Lee read

I will have a look. I will be running an st170 head. Where can I get runners or is it a case of ally tubes and fit on??

big_wasa

With the st170 head you may well need the 45mm trumpets.

nixon_2wd

I would probably

1. Simulate my engine in gt suite to find the optimum runner diameter, length, plenum volume with regards to max average gas velocity for the given application / rpm range.
2. Design and flow simulate an intake with the resulting parameters from the above
3. Revise my design based on simulation results
4. Make molds
5. Sand cast and machine it to spec
6. Never get around to test it

Turbo Zetec

iTrader: (1)

It's a 1.8 lx sapphire. there are some pictures in the project section but i've not updated it for some time now. it's now a bit above LX spec with electrics all round including sunroof and AC bulkhead and heater box

still looks like a faded red lx though

Turbo Zetec

iTrader: (1)

not much boost right now, only around 1 bar maximum as it's not been mapped properly yet. To fit mine in the sierra bay it had to be cut fairly short to clear the brake servo, then the neck had to be shortened and angled differently to give it a chance to link to the intercooler. I also drilled the new throttle plate (now a block) for the ISCV.

zetaboostboy522bhp

Yes mate , I've got x4 air horns you can buy if you want them , brand new never used

cheers paul

Lee read

Thanks Paul are they 45mm? If so let me know a price

zetaboostboy522bhp

Hi mate yes I have got x4 , they are 48mm but they have holes drilled in them as I had them with my turbo plenum.
the holes are for mounting them to the back plate
Ł60 plus postage about a fiver

cheers paul

Lee read

Ok Paul that's great thanks mate I will have them of you for sure. Will let you know when. Will be fairly soon

Lee read

is there any reason why I couldn't get that to fit on a zetec?

big_wasa

Plenum, yeah but the manifold and trumpets port spacing is miles out.

Again for the plenum the Nissan Pulsar Gtir is very popular, if you can find one.

Also a firm called Ike engineering is worth a look.

Lee read

I was going to just use the plenum as shown in picture and then build up the bottom end of it to match head