Evening!

I'm mucking about (slowly) putting a blacktop Zetec engine into my Stylus. I'm planning on using GSXR 600 TB's on an ST170 manifold. I offered the manifold up to the engine after work and noticed that the ports are different between the ST170 manifold and standard Zetec head leaving a rather nasty step- see pic:


ST170 Manifold Std. Zetec head

I spoke to google and some stuff came up about it on some Ford tin-top sites but not a lot if you force it to look in locost builders. They suggest some relatively crude bodges that I wouldn't do (removing the compression limiters from the bolt holes and lowering the manifold to leave a smaller gap top and bottom rather than one large one at the top). Has anybody else noticed this and done anything about it? Obviously it's pretty poor in flow terms, and I'd rather get it right and only do it once!

I guess my two options are:
1) Whip the head off and get busy with a dremel/grind stone/etc (and hope there is enough metal behind it! I assume so if the ST170 is this shape?). I've never tried 'porting' a head before- is it particularly difficult?

2) Get one of these off fastdan and use the GSXR injectors instead of the ST170 ones I had been planning
Ford ZETEC Bike Throttle Body Inlet Manifold | eBay

My preference would be to get a fastdan style manifold that would take ford injectors/fuel rail as I already have the bits and its easy! If anybody knows of one let me know.

I'd be interested to know what anybody else has done/would do/any better ideas!

could you put a 10mm ali plate between head and manifold and match inner and outer ports to form a smooth tranisition?

I would go with option 2) and sell the st mani to help fund.

Big wasa I think you may be right. Although ironically I may have just reduced their value!

It's a pretty big step Will- sorry the picture isn't great. It would still be a pretty bad flow path with a 10mm plate in it although it's a nice idea!

Will this really have a huge affect??

Many people on here have used this manifold and i also planned to ...

Cheers

loads of info on the net about the ports being taller on the st, most use them as there cheap and easy.I wouldnt open up the head to match a cheap manifold.

I did what will121 suggested and it worked very well.
As a supplementary question. What are you going to do with the step between rubber connectors and entry to ST170 manifold? That one isn't so easy to overcome.

You will need to make some form of plate as on my head the lower edge of the sealing rubber kept getting sucked into the inlet tract on full throttle. funnily reusing the old seal cured the problem as it forms a square section over time.

ATB Dan.

Dusty- I was going to take a flap wheel to it and smooth it all out. Leaves you with a step from TB to rubber still but I don't see that as being so bad.

I've asked for some quotes for a fabricated manifold with Ford injector locations, I'm going to give the ST manifold a miss. I know it will work and is fine for many, but it will drive me mad knowing its there! Slight OCD perhaps, but I'd end up pulling it off and doing it again so I might as well do it once.

Although Bogg Bros want £200 plus VAT!

I ran with ST170 manifold, spacer plate, fords mounting rubbers and GSXR throttle-bodies for 2 years. All the steps had been smoothed off to allow best flow. In the end I bit the bullet, bought a decent manifold and jenveys. Gained about 7 BHP on the rollers so my 'flowing' of the inlet tract was not so good.
I have eventually accepted the spend the money and do it right first time motto. Saves money in the long run.

quote:

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Originally posted by Dusty
I ran with ST170 manifold, spacer plate, fords mounting rubbers and GSXR throttle-bodies for 2 years. All the steps had been smoothed off to allow best flow. In the end I bit the bullet, bought a decent manifold and jenveys. Gained about 7 BHP on the rollers so my 'flowing' of the inlet tract was not so good.
I have eventually accepted the spend the money and do it right first time motto. Saves money in the long run.

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Hi will a rover zt 1800 inlet fit stright on to a Zetec 1.8 silver top if so could I still use the Zetec sensors and throttle body?

Martin

No it's not a direct bolt on. You either re drill the head or use an adapter plate. My experience is there not a fantastic match on the ports either. ( I tried two )
Throttle body is the same non fit. Most chop the end of the manifold and weld a new flange on.

Everything is a compromise but It's not the way I would go.

[Edited on 17/4/16 by big_wasa]

Right ok it's that bad of a fit then.... What would you recommend I wand to use the Zetec ecu and sensors etc can you modify the Zetec manifold.

There 1001 ways of doing it.

Re the manifold, silver top use side feed injectors black top use end fed injectors.

Westfield used the standard plastic manifold with a plenum to an air box mounted on the scuttle. Problem is the steering column need routing around it. (Got the plenum and air box )

Tiger used the up and over escort manifold. Problem is it sticks through the bonet.

I used my own version of the ginetta / griffin manifold. Problem is neither are available new or used and don't have provision for an idle valve.

Gbs make one. Problem is it's not Locost and no provision for idle control valve. The idle valve can be got around by manually adjusting the throttle stop.

If your building from scratch then the westfield set up is very neat and very cheap some photos.

here
http://www.sovereigncarsales.co.uk/Replicas_gridpos1.aspx

But you will need to move and modify the steering column down link and chassis cross brace.

That's brilliant thanks for that.
Might try the Westfield route without the big pipe to the front.

Is there much more power to be had by changing the standard intake.

With the above setup your looking at 145bhp tops but it is cheap with a standard ecu available for very little.

Realistically you could have it in and running and iva ready for beer money.

Bike throttle body's, megasquirt, mapping ect is a lot of cash for another 20bhp.

Jenveys and omex is serious cash for the same 20bhp

Besides get it on the road cheap and it will give you years of options for upgrades.

Sounds good to me I've fitted st170 down pipie too and took the cat off

Go the other way with mine. Its an ST170 engine with a zetec manifold. I just knock out the metal sleeves on the manifold and moved it up to match the ports.

Kitspares - http://www.kitspares.co.uk/index.php?route=product/product&product_id=628

and

Pepper performance - http://www.pepperperformance.com/rwd-zetec-plenum-chamber/

do the plenums to take the stock bits, don't forget to build in the MAF into the inlet before the TB otherwise the ECU will struggle.