Exhaust - What to do???

[Enoch]

Hi guys, I now have my engine and box in and have started wiring but want to turn my attention to the exhaust - the idea being to then complete the wiring and stir the beast in to life
I am using the I4 DOHC and would have to modify the downpipe to make it fit or buy a 4 branch manifold kit such as one from pepper performance. Has anyone gone this route? I can't see how the 4-1 collector could be welded without specialist gear - it looks virtually impossible to get round the pipes to weld them in place, particularly with a mig welder
I want the pipe to come out quite low in the car so it goes through the side panels and not through the bonnet. Pepper do a 4-2-1 and a 4-1 but I don't know which one to go for or whether to mod the original and save myself 100 quid.
Any thoughts or guidance would be much appreciated.

[teun]

Hi i do have the 4 in 1 set from pepper but i cannot use it. it is just a bag with pipes So 100P + shippingcost i wish i did buy some other stuff for that money.

[HandyAndy]

Hi Enoch,
I,m using a different engine ( 1.8cvh ) so not really that helpful, but what i did was to buy an exhaust manifold off an Escort RS1600 turbo which thankfully is a pretty good match for the outlet ports & is also a perfect fit for the bolt position.......anyways, the reason for this is that the manifold has a "square ish" flange where the turbo used to be sited which allowed me to make up a flange & welded the downpipe from that ( I believe Adrian H did the same sort of thing, it was Adrians, build blog that gave the idea), i may also use some of the "flexi pipe" exhaust to create the bend to exit thru the side panel.

Excuse my ramblings but is there a similar manifold that will fit your engine to do similar mods to, or even use the original manifold "cut n shut" without lots of pipes needing to be welded together?

cheers
andy

[ozzy1]

Teun,
Could you elaborate on the kit from pepper as was looking at this route.
Are the parts supplied shit or of no use to achieve a good fit or ????

[davidimurray]

When you weld up a collector, you normally bring the pipes together, tack them so they all touch - then make an infill piece to cover the gap between the pipes where they join and weld that in. You then slip the collector over, and weld all around the outside of the pipes. This should then give you a full sealed collector.

This will explain it better - http://www.coneeng.com/weld_on_collector_kit.html

but instead of having the merge bullets you fill the gap with a bit of flat plate.

[teun]

Ozzy1 i did buy the kit from pepper performance i did get a big bag full with differend pipes. I think about 15 pieces different size's some are straight some are bend if i do no forget i take a picture this weekend. The collector doesn't fit because it is to small. I would think twice to order the set.

[Enoch]

Hi all, Thanks, Tuen, I was a bit worried about spending that sort of money as the pictures they have on ebay are not very clear and I like to know what I am getting.
Andy, as far as I know the manifold I have is thge only Ford one that fits, I don't know if the unit from a 16 valve version would fir or if it would make life easier.
David, thanks a lot for that web link, that really helps a lot. The pepper pipes don't seem to go together anything like that but it shows a bit of the process.
I have emailed papper so I will let you know what they say. I have asked for some dimensions so I can see if it can be made to fit. I may have to just modify my down pipes.
Thanks for the replies, I will let you know what happens.
Best and all that,
Enoch

[Big Vern]

Hi Enoch,

From memory, I'm pretty sure the cast manifold you have is the only one made for that engine.
The 16v head/manifold is totally different. It might be possible to use the 16v one if you cut the flange off and make one that suits the 8V head but thats a lot of biggering about in my opinion.
Make something to fit the stock 8V outlet - possibly adapt the original downpipe.
The 8V is not a high performance engine so it's not like it's gonna affect performance much using the stock manifold.

HTH BV

[Enoch]

Well I had a very long chat with Spencer at pepper performance, he seems like a really helpful guy and spent quite a bit of time telling me how his kit goes together. It is somewhat helpful that he has a roadster there which he can use to make sure it will all fit I have bought a kit from them, he has said that if I have problems welding it together I can tack it, send it back and he will weld it for me for about the 25 quid mark. Happy days!! I will report back once I have the kit and will let you know how I get on. Tuen, It is well worth you giving Spencer a ring, he seems like a really helpful guy. Let me know i you need his number and I will PM it to you.
Enoch.

[Bonzo]

I'll second that Enoch

Spencer gave me some first class customer service & really went out of his way to help me