Zetec inlet plenum

[gaz05]

I've tried a few standard manifolds and all seem to foul the steering column so in true tightwad style I've decided to make one. Last manifold I bought was brand new from a 2.0L engine and it has most of the bits I need to stick on a fabbed manifold. The injectors and rail will fit well and the throttle body has all the gubbins needed.

I'm doing this because I want to use standard ECU as I just couldn't be bothered to run around getting stuff mapped etc. There's also the cost element of after market Ecus etc to think about.

I haven't got the gear to do Ali so yesterday I got enough 1.5mm steel plate to do this and the fuel tank.

First consideration was the pipes from flange to manifold. I know they should really have a bellmouth or rolled shape where they go into the plenum but it's too much chew to make them. I've decided to slightly flare the ends so there will be a degree of smoothness for the air to flow. That meant making a small former to pean them over.
http://i135.photobucket.com/albums/q135/gaz58/DSC04149.jpg

The plate was formed around a 40mm bit of solid bar and then welded. Once the weld was file flat at the end I put the former in the vice and slowly peaned them to the shape shown
http://i135.photobucket.com/albums/q135/gaz58/DSC04156.jpg
http://i135.photobucket.com/albums/q135/gaz58/DSC04150.jpg

The intention is to have a shaped plenum which is tapered. smaller at the front and getting larger to the other end which will have the throttle body on. It also means I can shape it to clear the alternator which on my engine is on the inlet side.

I'm not an expert the subject of plenums so anyone who wishes to offer advice is perfectly welcome

[gaz05]

I,ve also been experimenting with a boss to take the injectors. Slightly tapered at the top to accept the injectors.
http://i135.photobucket.com/albums/q135/gaz58/DSC04161.jpg

[Coozer]

Would have just been easier to route the steering arm round the plenum??

[gaz05]

It would have been Steve but because I've got the motor so far back every manifold I've tried on doesn't leave space for a coupling.

There is a manifold out there that only sticks out 180mm from the head but I've had a problem getting hold of one. This is the original Mondeo one.
http://i135.photobucket.com/albums/q135/gaz58/DSC04117.jpg

If this doesn't come out looking decent then I'll have to look at some other method

[Coozer]

Oops, just realised you showed me it before:) :)

Old age eh? What??

[gaz05]

You've got a few years before you catch up with me, young un

[David_17]

An EFI cast alloy one from an escort or fiesta rs1800 would fit. (don't know if the bonnet would go on though as it goes up and over instead of down like the rest)

[gaz05]

I've recently sold one of those David. It was Huuuuuuge. Would have been way above the bonnet line even without the throttle body.

http://i135.photobucket.com/albums/q135/gaz58/DSC04066.jpg

[gaz05]

Anyway, been doing a little research here.
http://horsepowercalculators.net/intake-manifold-design/intake-manifold-design
Seems the best method is to bring the pipes into the plenum and stop them above the floor of the plenum. They should also be rounded at the ends to help breathing so I spent a bit time peaning them a bit more by hand.

http://i135.photobucket.com/albums/q135/gaz58/DSC04168.jpg

The dimensions I'm using are probably not ideal but apart from neccesity I'm doing this just to see if I can.

I'm also going to incorporate the idle control valve and that's going to be complicated because the valve lets air into the plenum by bypassing the butterfly and taking it from an opening on the outside of the venturi.

[flyerncle]

Well done for the effort Gaz,you could use exhaust tube and save yourself a lot of work possibly.

Nice work.;)

[gaz05]

Little bit progress. The Manifold plate came yesterday and I'm a little dissapointed because it's not very accurate. The rear hole is about an eighth out. Wasn't going to worry about it but I've just realised the injector spacing means I'll have to place the injector off centre in that pipe..

I can't have that so I'll probably split it and build up the hole in the plate with weld and file out the other side and hope the damn thing doesn't warp. . Pain in the arse. TBH I'm getting a bit sick of this project. You order something online and look forward to getting it so you can progress and when you get it it's not right. I've actually found myself not being annoyed because I've come to expect it.

Thing is it's not just this but virtually everything I've got so far.

http://i135.photobucket.com/albums/q135/gaz58/DSC04174.jpg


Sod it. My weekend off and I was going to spend it in the garage. I'm just going to play on the bike instead.

[gaz05]

I haven't posted much about this because the manifold plate I bought from a reputable engineering firm on ebay was crap and has created so much extra work that it's ticked me off. I keep doing five minutes filing and then losing interest. it will get finished at some point.

http://i135.photobucket.com/albums/q135/gaz58/DSC04172.jpg

I've also had to make a new alternator bracket because the cut down original kept the alternator too high.
http://i135.photobucket.com/albums/q135/gaz58/DSC04178.jpg

[gaz05]

A little bit more today. Finally got the holes filed out and the injector bosses tacked in. Still a lot of tidying to do before I think about mounting the intakes.
Still need to file out one side of the port holes to line up with the ports on the head but nearly there now.

Some might have noticed that the injector rail is upside down. It fouled an intake bolt the other way so now needs to have the rail loom rewired.

http://i135.photobucket.com/albums/q135/gaz58/DSC04180.jpg

I may be putting the build off for a year. Well, not spending cash on it as I have a hankering to do Europe on the bike again next year.

[robo]

worth a read
bob

http://www.600scene.com/index.php?option=com_content&task=view&id=71&Itemid=32

[gaz05]

Still messing about with this.
http://i135.photobucket.com/albums/q135/gaz58/DSC04187.jpg

Intakes and injector bosses welded in. The intake angle has been lowered now the alternator is not in the way. I've also decided to have the throttle body facing forward so some adjustments have been done.

Been taking a while because I've also been finishing this

http://i135.photobucket.com/albums/q135/gaz58/DSC04191.jpg

[gaz05]

http://i135.photobucket.com/albums/q135/gaz58/DSC04195.jpg


Because I want to use the original ECU I've spent a lot of time figuring out how to utilise the idle control valve

http://i135.photobucket.com/albums/q135/gaz58/DSC04196.jpg
http://i135.photobucket.com/albums/q135/gaz58/DSC04199.jpg

[gaz05]

http://i135.photobucket.com/albums/q135/gaz58/DSC04197.jpg

Relatively pleased with it so far. Yes it'll be heavy but it'll get me going on ford ECU

http://i135.photobucket.com/albums/q135/gaz58/DSC04203.jpg

[gaz05]

Well, Its just about done.Needs a good wash out to make sure there's no crud in it and just tighten everything up. Fuel rail is rewired because it's upside down and mondeo plugs replaced the blacktop plug that was on.
Quite pleased with the finished result but it is a bit heavy!

http://i135.photobucket.com/albums/q135/gaz58/DSC04222.jpg

[big_wasa]

Looking good.

[gaz05]

Cheers Wasa. It's got a slight warp on the manifold plate but pulls up nice and tight when the bolts are in. Not sure whether to use a thick gasket paper or the gasket with the rubber seal in it. I've got a new one of those but might go for paper. And hermetite of course!

[big_wasa]

I use a thick paper.

http://i442.photobucket.com/albums/qq148/big_wasa/SDC10297.jpg