Zetec Turbo Inlet Manifold, BLING BLING!!!!
23-06-2004, 10:29 PM
#1
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Zetec Turbo Inlet Manifold, BLING BLING!!!!
This is my new inlet manifold that I picked up tonight. 
After making all the pieces up like a jigsaw puzzle it is finally welded up and polished after several months of design and sourcing the bits.
Bellmouth tapered runners towards the valve to accelerate the air.
Tapered plenum to prevent No. 4 getting to much air.
Will be fitting this in the winter to my car with the 1000cc injectors and the other bits and bobs I have in boxes lying around the garage. (Top secret)
Then get the engine re-mapped on the dyno.
Still using the modyfied Rover 220 inlet at the moment giving good power and torque. (It will be for sale after summer has passed if anyone is interested, complete with 480cc high Ohm injectors?)
Thanks to Lee at Fusion who did a good job of the welding & polishing
[/img]
After making all the pieces up like a jigsaw puzzle it is finally welded up and polished after several months of design and sourcing the bits.
Bellmouth tapered runners towards the valve to accelerate the air.
Tapered plenum to prevent No. 4 getting to much air.
Will be fitting this in the winter to my car with the 1000cc injectors and the other bits and bobs I have in boxes lying around the garage. (Top secret)
Then get the engine re-mapped on the dyno.
Still using the modyfied Rover 220 inlet at the moment giving good power and torque. (It will be for sale after summer has passed if anyone is interested, complete with 480cc high Ohm injectors?)
Thanks to Lee at Fusion who did a good job of the welding & polishing
[/img]
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24-06-2004, 08:15 AM
#8
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Hi Sunny
Last time it was dynod it made 350bhp at 6800rpm and 360ft lb of torque at 3800rpm before the injectors ran out of fuel with the Rover inlet and relatively low boost.
Not looking for more than 400 at the moment as the car weighs as much as a crisp packet. (probably only run 300bhp in the car)
Potentially it could make more than that if I wanted but it is hard to control at the moment running at 10psi
The car is 500kg with a full tank of fuel, but I would like to get it below this if I can
I am not really after chasing power figures at the moment.
I am trying to make the car as responsive and drivable as possible. (hence the new inlet)
Been to a few track days with friends (Cadwell Park), who have fast Caterhams / Lotus Exige's and was amazed by the amount of responsiveness the cars had round the bends.
Responsiveness on a windy road or track can win a race over the higher powered car as we found out at Cadwell racing some of the GT Porsche turbos.
Whats happening with your car at the moment? What's your new mods?
Last time it was dynod it made 350bhp at 6800rpm and 360ft lb of torque at 3800rpm before the injectors ran out of fuel with the Rover inlet and relatively low boost.
Not looking for more than 400 at the moment as the car weighs as much as a crisp packet. (probably only run 300bhp in the car)
Potentially it could make more than that if I wanted but it is hard to control at the moment running at 10psi
The car is 500kg with a full tank of fuel, but I would like to get it below this if I can
I am not really after chasing power figures at the moment.
I am trying to make the car as responsive and drivable as possible. (hence the new inlet)
Been to a few track days with friends (Cadwell Park), who have fast Caterhams / Lotus Exige's and was amazed by the amount of responsiveness the cars had round the bends.
Responsiveness on a windy road or track can win a race over the higher powered car as we found out at Cadwell racing some of the GT Porsche turbos.
Whats happening with your car at the moment? What's your new mods?
24-06-2004, 08:21 PM
#12
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Spot on austin , Have mailed you ref stuff .
for those that dont know austin , i must say he is one of the most inteligent blokes i have met in a long time and if he didnt look so good in a suite he'd give most of the so called tuners a fooooookin good run for their money .
Well done austin , hope it all works for you .
for those that dont know austin , i must say he is one of the most inteligent blokes i have met in a long time and if he didnt look so good in a suite he'd give most of the so called tuners a fooooookin good run for their money .
Well done austin , hope it all works for you .
24-06-2004, 08:38 PM
#13
DEYTUKURJERBS
Is the plenumn flow tested? Ie tested so under pressure theres equal flow to all cyls?
Jus for example with GTR plenumns which are similar looking, on boost the furthest cyl gets a lot more air than the others (tho off boost its the nearest that gets most)
Awesome all-round car tho
Jus for example with GTR plenumns which are similar looking, on boost the furthest cyl gets a lot more air than the others (tho off boost its the nearest that gets most)
Awesome all-round car tho
24-06-2004, 10:22 PM
#14
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Thread Starter
Zetec Turbo Inlet
Just finished building up the manifold tonight.
Gave it a good clean and polish and assembled all the bits.
1000cc bosch injectors
Ported cossy 4x4 throttle body
Gave it a good clean and polish and assembled all the bits.
1000cc bosch injectors
Ported cossy 4x4 throttle body
24-06-2004, 10:51 PM
#16
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Spent alot of money this time round so I wanted to get it right.
I'm a bit of a perfectionist so i'll be changing a few things over the winter.
This inlet will have pride of place on my mantle piece until it gets fitted on the car next year.
I'm a bit of a perfectionist so i'll be changing a few things over the winter.
This inlet will have pride of place on my mantle piece until it gets fitted on the car next year.
07-08-2004, 08:23 PM
#17
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Just removed the bulky cossy TPS and swapped it for one 1/4 of the size.
Should give me a bit more clearance under the bonnet.
Also fitted a F1 type fuel pressure reg to the rail.
Just got the goodridge connectors and fuel hoes fitted too
Looks even better now.
Should give me a bit more clearance under the bonnet.
Also fitted a F1 type fuel pressure reg to the rail.
Just got the goodridge connectors and fuel hoes fitted too
Looks even better now.
04-11-2004, 11:39 PM
#19
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Had a re-think and decided to make a few mod to the inlet.
Gone to 8 injectors spaced in two banks.
Lower bank close to the valves for low revs and emisions.
Upper bank are near the trumpets for higher revs and boost which will give a better mix with the air
Both sets are run banked which should also aid throttle response over sequential
Gone to 8 injectors spaced in two banks.
Lower bank close to the valves for low revs and emisions.
Upper bank are near the trumpets for higher revs and boost which will give a better mix with the air
Both sets are run banked which should also aid throttle response over sequential
29-11-2004, 08:18 AM
#26
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AustenW,
Do you know Scooby on the Westfield owners club forum (www.wscc.co.uk)?. He comes to the Manchester area meets and has just fitted a turbo to his zetec. I don't think its on the road yet but he's had it running.
Mine's quick with a 115bhp 1.6 cvh on twin 40 dcoes, yours is going to be embarassing owners of very expensive cars.
Did you go to any of the shows this year by the way and will you be going to any next year?
Kirk
Do you know Scooby on the Westfield owners club forum (www.wscc.co.uk)?. He comes to the Manchester area meets and has just fitted a turbo to his zetec. I don't think its on the road yet but he's had it running.
Mine's quick with a 115bhp 1.6 cvh on twin 40 dcoes, yours is going to be embarassing owners of very expensive cars.
Did you go to any of the shows this year by the way and will you be going to any next year?
Kirk
29-11-2004, 06:07 PM
#28
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Originally Posted by kik1.6se
AustenW,
Do you know Scooby on the Westfield owners club forum (www.wscc.co.uk)?. He comes to the Manchester area meets and has just fitted a turbo to his zetec. I don't think its on the road yet but he's had it running.
Mine's quick with a 115bhp 1.6 cvh on twin 40 dcoes, yours is going to be embarassing owners of very expensive cars.
Did you go to any of the shows this year by the way and will you be going to any next year?
Kirk
Do you know Scooby on the Westfield owners club forum (www.wscc.co.uk)?. He comes to the Manchester area meets and has just fitted a turbo to his zetec. I don't think its on the road yet but he's had it running.
Mine's quick with a 115bhp 1.6 cvh on twin 40 dcoes, yours is going to be embarassing owners of very expensive cars.
Did you go to any of the shows this year by the way and will you be going to any next year?
Kirk
Went to all the shows this year but not in the car as I had a slight bump mid summer
Will be at all the shows next year.
hexxon
Yes did some calculations for the inlet, and it works
It is slightly tapered and the trumpets do go quite a way into the plenum
30-11-2004, 09:18 AM
#29
Part of the Furniture
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Hi Kirk hows it going.
I live here too.
Mr Austin W was kind enough to sell me some of his quality products. CHEERS AW.
I should be up and running in Jan 05...
I live here too.
Mr Austin W was kind enough to sell me some of his quality products. CHEERS AW.
I should be up and running in Jan 05...
30-11-2004, 11:56 AM
#30
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Hi Scooby,
Is yours on the road yet?
They've started salting the ground now so i won't be driving mine for a while.
I've just noticed that AustenW's reg is RS WST, the name he uses on the WSCC forum.
Should see you at the next meet or the meal.
Kirk
Is yours on the road yet?
They've started salting the ground now so i won't be driving mine for a while.
I've just noticed that AustenW's reg is RS WST, the name he uses on the WSCC forum.
Should see you at the next meet or the meal.
Kirk
30-11-2004, 11:29 PM
#31
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Originally Posted by AustenW
hexxon
Yes did some calculations for the inlet, and it works
It is slightly tapered and the trumpets do go quite a way into the plenum
Yes did some calculations for the inlet, and it works
It is slightly tapered and the trumpets do go quite a way into the plenum
03-12-2004, 04:02 PM
#32
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Thread Starter
Originally Posted by hexxon
Originally Posted by AustenW
hexxon
Yes did some calculations for the inlet, and it works
It is slightly tapered and the trumpets do go quite a way into the plenum
Yes did some calculations for the inlet, and it works
It is slightly tapered and the trumpets do go quite a way into the plenum
Plenum was calculated using good old pen and paper maths, and is tapered to avoid forcing air into No. 4
Thought about using cfd for it but I'm not after chasing figures and don't know how to use the software yet
Should be good enough for my needs, only looking to run 300bhp.
Are you building a manifold for your engine?
03-12-2004, 04:46 PM
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Ok. Sounds well.
Cfd is no easy issue at all. Not if you want to use it properly, keeping things as close to reality as it is possible with the physical laws given.
Yes, im building a inlet manifold for my YB.
Cfd is no easy issue at all. Not if you want to use it properly, keeping things as close to reality as it is possible with the physical laws given.
Yes, im building a inlet manifold for my YB.
Originally Posted by AustenW
It is based on a Jenvey system, manifold, inlet trumpets etc. I'm sure these guys have done alot of testing using cfd as they supply most of the touring and rally car teams.
Plenum was calculated using good old pen and paper maths, and is tapered to avoid forcing air into No. 4
Thought about using cfd for it but I'm not after chasing figures and don't know how to use the software yet
Should be good enough for my needs, only looking to run 300bhp.
Are you building a manifold for your engine?
Plenum was calculated using good old pen and paper maths, and is tapered to avoid forcing air into No. 4
Thought about using cfd for it but I'm not after chasing figures and don't know how to use the software yet
Should be good enough for my needs, only looking to run 300bhp.
Are you building a manifold for your engine?
03-12-2004, 05:58 PM
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Well its getting nicely along actually. The design has been more or less finished for half a year. Whats left is the manufacturing, which is not common weld-job actually. The plenum will be milled out of two solid billets of aluminium in a rather extreme mill, using CAM-preparation, leaving lots of interesting details out
The plenum is in its current form only a couple of 3d-surface-models. I dont want to share them... Pictures will perhaps be shown of it when ready.
The plenum is in its current form only a couple of 3d-surface-models. I dont want to share them... Pictures will perhaps be shown of it when ready.
03-12-2004, 06:29 PM
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As for now, this early prototype will be built as a wide-range high torque 400 bhp. Will not be for long though. Taking it out this summer for some testing and track day use...
Originally Posted by AustenW
What power you looking for?
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