Zetec Conversion Exhaust Manifolds

[StrawberryCheesecake]

Hi All

What experiences and tips have people got for zetec conversion exhaust manifolds.

My vague plan is to buy a conversion manifold for a Mk1/2 escort and cut and shut it to make it fit round the Europa Body, engine mounts, etc. There are various types available from the cheap and cheerful Ashley at £230 ish to stainless ones around £500-700.

I don't really want to chop up a £760 Simpson manifold. Might as well get one custom made at that point. TBH I'm leaning towards mild steel rather than stainless anyway.

I also noticed that the standard duratec manifold looks to be quite a good design, and might be adaptable. Does anyone know if the Duratec exhaust manifold fits a silver top zetec? Probably not but you never know.

https://www.ebay.co.uk/itm/Ford-Focus-Zetec-Duratec-ST170-Exhaust-Manifold/382558339857?hash=item5912410311:g:Pn4AAOSwL1hbkXOJ

http://www.burtonpower.com/ashley-exhaust-manifold-16v-ford-zetec-e-escort-2-25-bore-ashm07.html

or at the top end of the range
http://www.burtonpower.com/simpson-exhaust-manifold-16v-ford-zetec-e-escort-mk1-mk2-rhd-simpm01.html

[BDA]

A friend of mine is building a Zetec S2 and get some very nice headers from a company in England. He sent them some measurements and they made them up. I would expect that they could reproduce them. I posted some pictures of them here: http://www.lotuseuropa.org/LotusForum/index.php?topic=2039.msg19162#msg19162

If they look something that interests you, I can find out who did them and PM you.

[LotusJoe]

I went the easy route. These exhaust are readily available and inexpensive.

[StrawberryCheesecake]

Thanks both for the info. I'm planning to upgrade the engine at a later date, so trying to plan for something that will cope with around 180-190 bhp (2.0 Zetec, twin weber 45s, uprated cams and increased compression, mappable management and high octane fuel, although I'll start with the stock cams and compression just to prove the system, and 150-160 bhp should be enough to enjoy the car for a bit.

BDA, I would be interested to know who built those manifolds. I wonder if anyone would be interested in a group buy?

I found out that the ST170 manifold probably will fit the head, and I think it looks like quite a decent design, which could be easily adapted as it's mild steel.

My cousin's ex husband makes titanium exhausts for Ducatis. I'll probably ask him to make me a system for it in the end, but in the meantime, I'll start with a system made from some ex Renault Clio Touring Car racer exhaust bits that I acquired.

Pics of Titanium Ducati system from a race bike that he made - attached for interest. Apparently they're about 130 hours of work per system, because of all the bends and diameter changes.

[jbcollier]

I want to have that exhaust’s children!

[BDA]

Beautiful work! I've emailed my buddy for information about where he got his headers. I'll post what he tells me.

[BDA]

My buddy got back to me. Here's his email to me (he's Swedish so cut him some slack on his spelling):

Hi Jim,
 
Yes , there was Dunnell Engines in UK who did it and I told the boss Paul
Dunnell if there is anyone who like to get the same headers he could go ahead
and make some because he have the drawing for the header . And that person
probably will bet the header cheaper then what I pay for the header .Phone
number is 011-44-1449-677726. Email:admin@dunnellengines.com
 
Tell the guy when he order the header that he want Kenneth Andersson Lotus
Europa Zetec header, then Paul know what it's all about . I can't find the
recite for my header what I payed for it , but I think it was around $1200 plus
shipping.
 
Ken

[StrawberryCheesecake]

His English is better than most natives

Thanks for the info - Dunnell are a major name in Zetec tuning.

[StrawberryCheesecake]

I think this could work. Aiming to cut & modify just after the 4:2 join