I am currently designing an aluminum inlet manifold for my zetec engine. (2ltrs have a nasty plastic thing).

It is an eight injector design loosly based on the sierra cosworth one. It will accept the standard 2ltr zetec throttle body (same size as cosworth one 59mm) and Bosh top feed injectors (most common type in scrappies and big range).

It will come complete with fuel rails and would be an ideal setup for any one that wants to turbo charge your zetec.
It would also be a much cheaper alternative to throttle bodies for NA.

My question is, it would be fairly easy for me to double up my quantities and build another one at this stage, would anyone be interested in it?

Certainly would. I was planning on using carbs, but I would be very interested in one of these. The engine I am using had one of those big lumps of black plastic. Would I be able to use the bits of it? Not sure if this picture is of any use to you, the person who built this used a standard escort (metal) inlet manifold and chopped it as it came away from the block, then welded on a stainless tube, and a flange for the throttle body.

[Edited on 27/11/03 by Big Stu]
Rescued attachment shineplenum.jpg

You will be able to use the throttle body and the idle valve off the horrible plastic thing.
Are you going to run programmable engine management or the stock stuff?
Its just i have designed the manifold to use Bosch top feed injectors for a better choice of flow rates and not those horrible Ford side feed items.
If you want to run stock management I'm sure i could find you some Bosch injectors with a similar flow rate and impedance to the ford items.
My manifold should look a bit better than that. I think the best idea is if i cut/turn two lots of material but only get one welded up. That way you can take a look at a finished item and see if is still for you?

If I was going to be using the system I would probably use the stock injectors as I already have the ECU for the engine. It is a test ECU and therefore can be used with the minimum of sensor, ie no need for things like imobilsers etc...
What material are you planning to use for this, and any idea of the rough cost?

The manifold will be made from aluminum which i could probably polish if you like your stuff shiny!

As for cost i will have to let you know as it really depends on the welders costs but i should imagine between £100-200, with £200 being an extreme!
Like i say i'll get one made up and you can see what you think.

I take it you are using a programmable ECU? I don't think the standard item can be programmed to fire the two banks of injectors correctly, and if it could you would still need to rolling road tune it. Unless you are going for 225+BHP I would have thought 4 injectors would be fine, and at this sort of level of tune throttle bodies would be far better as the single original one must be getting beyond its design limits.

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Originally posted by zetec
I take it you are using a programmable ECU?

Emerald ECU (or Megasquirt n EDIS for experimentation). Dave Walker will map any setup for £230 inc vat. He said eight injectors usually work very well. One of the last CCCs had an article where a guy gained 15bhp on a NA engine by using a second bank of injectors upstream for better atomisation.

I don't think the standard item can be programmed to fire the two banks of injectors correctly, and if it could you would still need to rolling road tune it. Unless you are going for 225+BHP

250-300 bhp with a bit of luck. 2.1 turbo zetec with forged low comp pistons.

I would have thought 4 injectors would be fine,

Four injectors with flow rates that will support 300bhp are very expensive. Run eight smaller ones that cost pennies from local scrap yard.


and at this sort of level of tune throttle bodies would be far better as the single original one must be getting beyond its design limits.

Not a problem if you are pushing air through it with a dirty big turbocharger!
Like i said before, stock 2ltr mondeo item is the same size as cossie item and we all know how many ponnies they are good for!

If you were going NA it would be a good replacement for the horrible pastic one. You don't have to run all eight injectors, just the first bank. Throttle bodies will flow better for high horse power NA applications but not every body has that sort of cash (£1000) sat around.

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I got my Emerald ECU and throttle bodies for £1000 brand new...The throttle bodies work out about £450 the pair.

Thats a good price. I always thought they were more than that.

How are you getting on with your emerald ECU?

Any comments or recomendations?

Would appreciate your feedback as i'm about to buy one myself.