I have just finished cleaning the inlet manifold and injector manifold for my Zetec conversion and am rather appalled at the poor port matching. I am using the 1.8 zetec Escort inlet manifolds as part of my 2.0ltr Zetec conversion on the Escort.

The problem is largely with the injector manifold. where it mates with the inlet manifold tract, it is flared and so becomes larger than the inlet manifolds tracts.

I had a similar problem with the original engines manifolds (1.6 CVH MFi) and simply flared the manifolds ports to match. However, this creates a large 'pocket' in the inlet tract which will no doubt upset the air flow and the final engine performance was a bit dissapointing.

The only other option I can see it to fill the flared portion in and regrind to match the inlet manifolds tracts. However, I am now a bit concerned as to how well any filler (proper alluminium filler/chemical metal) will bond to the manifold and stay put. I doubt the cylinder head will thank me for injesting bits of filler.

Does anyone know of anything available that would fit the bill? I have thought of alluminium welding but was hoping to avoid that as there are still issues with bonding (cheap ally castings) and getting the face reground to get it flat again.

Or is there any other sollution?(I know that sticking bits of filler in the inlet tract seems a bit cowboy like but how else can I overcome this step?)

Would I be best to just leav it as it is?

What do you tunning boys do?

Any help would be greatfully received.

Cheers,
Smiler.

 

On the N/A Milington engines they leave a step between the inlet and head. Aparently it creates turbulence and gives a better fuel air mixture,thats good for 10bhp. And thats coming from a guy I spoke to with a Ł15k normally aspirated motor pulling 300bhp in a westfield.

 

I can see how that would work, it is after all less than an inch upwind of the injector.

Thanks for that.

Smiler.

 

Smiler me ol'mucker,

A little bit off your topic but https://passionford.com/forum/viewtopic.php?t=54222

Am confused as to where to drill the holes, am using your guide from your site, just wanna make sure i get it spot on.

 

hmmm, my cab came with the holes already there from the factory. Best bet is to go to your local breakers and find either a suitable Escort or an Orion 1.6i that's up in the air. Come to think of it, any mk4 shape shell should have the holes presernt. Then take some measurements.

Sorry I can't be much more help mate.

 

Well thats sods law that is! I wonder why mine didn't?

Anyway, hows you mate? Have you seen my restoration link?

https://passionford.com/forum/viewtopic.php?t=42288

Soon, very soooooooooooooooon!

 

not bad, my car was a very late mk3 shell and so had many of the mk4 features such as the hole in the inner wing for the relocated large capacity screen washer bottle.

I haven't seen the thread yet, will take a look in a mo when I have more time.

Keep at it,
Smiler.