This started as I wonder if I could. so I cut down the inlet manifold then stuck on the milling machine to end up with a flat result.
I am wondering if anyone else has done this before and if there are any pre cut metal plates to mount runners etc. on?
It would allow use of standard injector rail and mounting, only downside I can see is the angle it goes down into the head, so means angles runners.

The normal Zetec lazer cut inlet plate can not be used as it is the wrong shape.


Plastic sandwich1

Plastic sandwich2

Plastic sandwich3

Plastic sandwich4

Just not finding the metal sandwich plates easy to come by anymore.

Adrian

Just resized pics to be a bit smaller size

[Edited on 28-12-10 by AdrianH]

Have you tried Boggle? I know he cust some good quality stuff for not a lot. There are others on here too.

andyw7de he'll do it for you i'm sure

Thanks for the posts, initially though I am wondering if anyone has gone this way before and I am wondering what others used with the aluminium sandwich plate if at all?

Adrian

Someone (can't remember who of the usual suspects) does do a plate that bolts onto the 'non head' side of that plate.

The work you have put into that would be no more than turning up four injector bungs and welding them to runners as per ginneta/griffin.

very jealous of the mill

Ive seen people cut the runners down to an inch ans bodge on some bike carbs/ Tb's but thats the first time ive seen it done like that.

quote:

---

Originally posted by MikeR
Someone (can't remember who of the usual suspects) does do a plate that bolts onto the 'non head' side of that plate.

---

quote:

---

Originally posted by big_wasa

quote:

---

Originally posted by MikeR
Someone (can't remember who of the usual suspects) does do a plate that bolts onto the 'non head' side of that plate.

---

Short track did a plate that would bolt to the escort/fiesta sandwich plate.

---

Thanks folks for the feedback, as I said, it just started as I wonder if?

Thinking more about it as as the plastic plate is 29 mm thick and the ali one is around 40 mm thick the ports will be in a slightly different place to the normal gasket.

I am about to try and find a drawing package for my SUSE 11.2 and download it. I will try to draw what I need and either machine it out or have it laser cut from something like 5 mm. It is all just a suck it and see as this engine will not be in a car for some time.

Adrian

p.s. Will121 thanks for the link.

[Edited on 28-12-10 by AdrianH]

Been playing again. Drawing package this time.


Plastic inlet plate ver 1

A jpg export of a dxf file, thinnest section is only 3 mm and wondering if possible?

Adrian

[Edited on 30-12-10 by AdrianH]

Hi folks, as i can see on one of the photos the plastic plate from the original zetec manifold can be cut and the new metal plate can be mounted on it (probably with a gasket) and from there to start the plenum. This is a way to use the original injector seats and fuel rail mounting spots isn't it? Ou now i see thet the metal plate should be modyfied...
Yavor

[Edited on 20/1/11 by i_froloshki]

But please note, the standard metal plate available that mounts to the block can not be used as the ports are now in the wrong place they need to move upwards.

Adrian

[Edited on 20-1-11 by AdrianH]

Got two plates cut by Andy from here, turned up today and I am very pleased for my first real attempt at CAD at just how close they are to the ports on the plastic manifold considering non of them seem to be on a straight line.





It takes me time to get around to these things but I will get there eventually.

Adrian

[Edited on 21-6-11 by AdrianH]

The plenum that 'Kit Spares' sell uses a modified manifold in exactly this way. The flange that they use has a bit more meat above the inlet ports though. Shorttrack no longer do the flanges to fit the original zetec sandwick plate. They had 2 left 'out the back' when I contacted them (bought 1) and no plans to make any more.

I have assembled one and welded up the tubes and trial fitted it to the engine, not looking too bad up to now and looking at the spacing there is room for more metal to be left around the injector.




Adrian

GBS/Robin hood are now selling a plenum that uses the plastic manifold as a sandwichplate looks good quality aswell inlets are all trumpeted take a look on there site!

True, but I started last December, so I'll finish it. At least it shows the idea was not daft. Just taken me too long.

Adrian

just fitted my gbs inlet plenam and sandwich plate, I will post up some pics in a new thread.

A bit of time in the garage again today, welded up around the top of the tubes and bent a plenum box. Not sure which way to have the inlet either at the scuttle end or down by the radiator area. Thinking of the scuttle area as a preference at the moment.
Anyway a few pictures:





Still to do the trumpets and inlet plate.

Adrian

[Edited on 9-7-11 by AdrianH]