Hello everyone!
I'm Ben, new to the Zetec engines and liking what I see on here. There's a lot of development here in RWD applications, and that's what I've got. I look forward to posting some pictures of my project, meeting other Ford enthusiasts, and hopefully getting some knowledge on the )mainly blacktop) Zetec engines.
I do have knowledge on other US Fords, as well as having cut my teeth on Jaguars, MGs, Triumphs and other 1950s-1980s European cars (and a few of the Datsun/Nissan Z cars)--so I'm not hopeless, and I know my away around under the bonnet, which way to hold a spanner, and why your hoods are more fun than the American style.

Now, for the reason I joined the forum, and I apologize if this is the wrong part of the forum to ask for advice.

My vehicle is a 1965 Volvo 122S "Amazon" with a blacktop Zetec-R which mostly fits. It was taken from a 2003 US market Focus ZX3, with a Type 9 gearbox behind it.
I'm not looking for big power (the Zetec is already lighter and more powerful than the Volvo block--which wasn't a bad engine either, but it was missing when I bought the car!). I'm looking for a clean and reliable installation.
The current install has some problems:
1. The intake is junk. The plastic one lands in the suspension, so I have a custom built unit that pokes through the front panel next to the radiator and is tight in every dimension. There's a heap of space for an "up and over" setup like on the (I think?) Fiesta XR2i. I'd like to find out about whether these can be fitted to blacktops, or if there are other options that might work and don't cost a mint.
2. The stock exhaust fits, but a decent set of extractors might fit better. US-market Zetec extractors are either very dear, or they tuck under the engine in FWD manner, or both. I might just weld a custom set and live with it.
3. The thermostat housing is VERY close to the firewall. Is there a lower-profile design available over there? I might just give up and buy one of the water rail kits. I have to figure out my water plumbing anyway (I'm keeping my heater, too).

I'm sure there are other things to consider, but that's enough for one post. I'm looking forward to meeting you all and looking at more of your projects as well!
Cheers!
Ben

 

Okay, I'll link some eye candy.

As I bought it, running, although just:

Engine bay; the upper hose is more clear of the exhaust than it looks (but less than I'd like); parts of the inlet tended to bang off the inner wing under hard acceleration:


The sharp-eyed amongst you will have noted, also, that the idle control valve was plumbed with both ports direct to the plenum and thus useless for actually controlling the idle. The PCV system was blocked off, the emissions items simply binned, the factory ECM lying in the trunk duct-taped to the Ford Focus ignition switch and part of the original instrument panel. The wiring is visibly...creative.

Midway through the work; unfortunately, I've moved so no longer have the wonderful garage with lift:






The new wiring is part custom built harness with part Focus harness. All emission and injection controls are being kept, and I'm using custom tuner with Ford OBD2 EEC-V ECM.
I don't know what the final paint will be but I might go with flat black or a different shade of blue. The interior is in great shape, if messy, and so I'll be keeping the light blue vinyl.

Cheers,
Ben

 

If you were right-hand drive then the exhaust headers wouldn't have to battle past the steering. You could get the detailed dimensions from a supplier of headers for Zetecs into 70's Escorts & Cortina's but not guarantee from diagrams that they would clear.

The hot-rod market over there is awash with talented engineers knocking up twin headers for V8's so surely there's a shop around your way that could build a set for your car (and only half the time and materials compared to a V8.

BTW - back in my younger days I would hanker for an Amazon to custom build. They are the spit for a mini Mercury and would take the low-rider style with ease. At least one was built in the UK, chopped and channelled 2-door with mock US chrome style front. I will search Google for some pics.

 

Here you go. Built by Andy Saunders around 1980 I think and had a number of reincarnations



A few more here - http://snail.s4.bizhat.com/snail-ptopic244.html

 

Hi, welcome, great project.

There are supplier/manufacturers in the uk that make custom thermostat relocation water rails and other parts for the fitting of zetec engines into rwd applications. I believe retro ford are one, I will see if I can find a link for you. http://www.retro-ford.co.uk/shop/con...-manifold-z008

To my knowledge the inlet manifolds are interchangeable between silvertop and blacktop engines so you could possibly go down that route.

 

Vacuman, there are some sharp Amazons out there! I'm actually fixing mine up for a daily driver, so I'm keeping the power low for good mileage, and the bodywork simple for easy repair. I've got a few fun cars (1980 Mercury Z7, 1999 Mustang, 2013 Mini Roadster) for other uses.

I'll probably make my own headers, although there's a good bit of room to clear the steering unless I stuff a turbo in there...but for that money, and my modest goals, I'd be just as well off to stuff a Ranger Duratec and 5-speed in and sell the Zetec/Type 9. If I were starting over, that's what I'd do. Again, daily driver, MANUAL BRAKES, armstrong steering...no need for big power.

Studabear, thank you for the link! I've looked at retro-ford and Burton and a few other places. The only common Zetec inlets in the US are the plastic Focus/Contour (Mondeo?) units that are right in my suspension upper pivot mount. I see something about a Rover inlet that can be adapted, but I suspect those aren't over here either.

The water rails are nice, but dear. I was hoping there was a Ford factory low-profile setup that was easily found in breakers over there; the plastic ones tend to crack and I have to pull my engine to get the bolts clear. The coil bracket hits too, but I'm adapting to coil-on-plug for a neater engine room anyway.

Is there a good website describing the inlet options?

 

Hi and welcome to the forum! the car looks like an interesting project

as for your questions, hopefully the following will help:

1. as far as i know, you can use the early xr2i type alloy inlets, the inlet port is a slightly different shape on the later engines but i think it has been done before.

2. take a look at the exhaust manifolds (headers) here:

http://www.ashleycompetitionexhausts.com/manifolds.html

3. water rail kits to relocate the pipework and thermostat can be found here:

http://www.ikengineering.co.uk/#!pro...water-rail-kit

http://www.retro-ford.co.uk/shop/con...-manifold-z008

http://www.dunnellengines.com/zetec_...partno=RMP1952

http://www.raceline.co.uk/products/p...5&CategoryID=2

http://shop.autospeed.co.uk/zetec-en...ater-rail.html

some are cheaper than others. i have a retroford one, it's very well made and looks good too.

 

Thanks for the links, Turbo Zetec!
Looking at XR2i brought me to the US-Market Capri XR2, which had a Mazda B6T engine, whose ports look familiar...I wonder if my inlet is a modified aftermarket Miata piece?
I've already moved the idle valve ports, maybe I could just blank the throttle body outlet on the face of the inlet and cut in a new one at the top. I'd still eventually like a more svelte OEM inlet, but for now just moving the throttle body might keep it from going *CLANK* against the wings and valance every time I load the engine.

That Dunnell water rail looks like exactly what I need; the Retro-Ford looks like it leaves the thermostat up against the firewall and doesn't look like it has heater outlets.

 

interesting project and different from most american classic cars.

If you need help with stuff from uk cars send me a pm, my friend goes to breakers quite often and ships worldwide so could help out. Keep us updated with how you get on