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.


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



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