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Thread: FIT A ZETEC - Part 2 - Exhaust

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    FIT A ZETEC - Part 2 - Exhaust

    Heres the second in a series to help anyone considering the Zetec Upgrade, I have compiled these posts from mainly information off the forums, so a big thanks to everyone who has shared thier data with us.
    I will be adding and updating these posts as we find out more so keep an eye on the edited date at the bottom of the post and reread it for the latest information.

    Exhaust:
    Manifold:
    The Manifold is the main problem; here is a couple of options I looked into, I finaly went the Ashley route as I found a Manifold for £50 secondhand.

    Option 1:
    Modify the Late Tublar Focus item (May come on donor engine), this will need some reasonable DIY Skills, the ability to weld and some offcuts of stainless
    tubing to mate it to the X-Flow 2¼" system.


    LATE FOCUS MANIFOLD

    Option 2:
    Buy an Ashley 4-2-1 manifold (£140 approx) these are well constructed, primaries are not equal lengh but they are very unrestrictive.


    ASHLEY MANIFOLD

    System:
    The Ashley Escort X-Flow 2¼" bore twin or single box system is the one to use (£110 Twin £92 Single)

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    I love to crap Decade Plus User PercyBigun's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    you can also get a 4:2:1 ceramic manifold for zetec from www.zxtuner.com (they list them for focus, contour and cougar) in USA - i got one with downpipe/decat pipe for approx £260 including shipping and import duty and it fit straight onto my mk1 2.0 zetec mondeo (silvertop). they also do a 4:1 shorty header (about £150 shipped)

    you can get a zetec manifold for single or twin turbo use here for £200 http://www.chevroletls1.com/zetecturbo.html

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    World Champion Decade Plus User markb's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    is a custom superfly equal lenth header manifold likely to add any significant gains oevr the ashley, bearing in mind they cost ££££££££ ?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    PercyBigun said:
    you can also get a 4:2:1 ceramic manifold for zetec from www.zxtuner.com (they list them for focus, contour and cougar) in USA - i got one with downpipe/decat pipe for approx £260 including shipping and import duty and it fit straight onto my mk1 2.0 zetec mondeo (silvertop). they also do a 4:1 shorty header (about £150 shipped)

    you can get a zetec manifold for single or twin turbo use here for £200 http://www.chevroletls1.com/zetecturbo.html
    They are all for FWD Percy ?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    markb_s1 said:
    is a custom superfly equal lenth header manifold likely to add any significant gains oevr the ashley, bearing in mind they cost ££££££££ ?
    It can make a world of difference if all the primaries are of the correct diameter and the corret lengh for the engine, the bore and lenghs vary with engine tune !

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    I love to crap Decade Plus User PercyBigun's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    the zxtuner.com 4:2:1 headers are for FWD but directly below the thing it has a bolty joint so you could bolt on or fab up what you want beyond that.

    the second one for the turbos is more for kit cars and custom cars etc RWD but looks like it would work on FWD aswell

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    Pit Crew Decade Plus User ludsonline's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    What size primaries/ secondaries are best?

    is 4-2-1 or 4-1 better?

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Dunnell do a tuned ZETEC manifold, it costs a few quid though.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    A tuned exhaust is not worth buying unless you engine is the exact same spec as the engine it has been tuned for.

    A good book that touches this subject is 4 Storke Tuning by AG Bell.

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Thats true to a point, but the Lotus guys get gains of up to 12 bhp by binning the OE manifoild and fitting a properly made 4-2-1. While others get nothing by fitting cheaper versions.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    I can understand that from going from OE to a tuned lengh pipe, in fact on the Duratecs I have heard more like 20HP, I would like to know what the difference would be from say the Ashley though.

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    I will try and get you a picture.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Where is the cheapest place to get a Ashley manifold from?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    I bought mine from... lol cant remember who i bought me manifold from was a few years ago, got a replacement system from speedshack though, they seemed pretty reasonable, dunno if its the cheapest, good service though

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Paul,

    The cheapest Ashley supplier is TJmotorsport.co.uk make sure you say that I sent you and they will do you a good price.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Oh and PLR do a really cheap exhaust system that fits the ashley manifold nicely

    Richard

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    RChambers said:
    Oh and PLR do a really cheap exhaust system that fits the ashley manifold nicely

    Richard
    21/4 inch ? and fits directly ? how much >?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Single box 2 1/4" is £80 and twin box is £85. Both are x-flow systems. Connects to the manifold fine and bolts to the bolt floor with two rubber cotton reels.

    Richard

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Picture please Mr Chambers

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Its a bit cold to lay on the floor taking pics hopefully take some tomorrow.

    Richard

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Yes would like a pic of that exhaust too, i guess its a case of drill holes in floor to mount job or does it mount on standard x flow location??? Also is it ashley or just budget???

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    IMO its better built than an Ashley but time will tell. No pics yet as I over done it at the pub and I've been indoors feeling sorry for myself . It does bolt through the floor so the old mounts aren't used. The system attaches to the manifold using a sleeve (which isn't included, bloody cheeky really). They never told me you needed a sleeve to bolt it on so if you buy it make sure you can get hold of one. I think the sleeve is a bit of a race feature tbh as it would allow the exhaust to move a bit without stressing the manifold, if you don't clamp it on that is. Pics soon I promise!

    Richard

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Oi you got any pics of the exhaust yet mate?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Clint said:
    I can understand that from going from OE to a tuned lengh pipe, in fact on the Duratecs I have heard more like 20HP, I would like to know what the difference would be from say the Ashley though.
    On the Duratecs for the Silhouette cars we are doing playing with the exhaust manifold gave an increase of around 15bhp after already impressive results.

    But on a friends Super Silhouette (XE 16V powered) a loss of 16bhp was the result of fitting a new (expensive) manifold from one of the best known and reccomended race car exhaust builders in the UK, so manifold design and tuning are very important and getting the primaries right is the place to start.

    The exhaust builder in question point blank refused to believe it was his problem, and only admitted it when the tuners showed him back to back results.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    What is a ST170 manifold made from?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    What is a ST170 manifold made from?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Quote Originally Posted by Zetec_Escorts
    Paul,

    The cheapest Ashley supplier is TJmotorsport.co.uk make sure you say that I sent you and they will do you a good price.
    Copetition parts uk do one for £114.24 ashley manifold

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    i can find competitionpartsuk.co.uk if thats it but cant get the site up???

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Quote Originally Posted by alladdin
    i can find competitionpartsuk.co.uk if thats it but cant get the site up???
    that should be it mate it was working the other day maybe try ringing them they are always in the back of classic ford mag

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    i shall keep an eye onthem ... going back slightly ... has anyone found an alternative to the (dont look the best balance) ashley. ???
    i have a stainless system ive picked up and id love a stainless manifold but all the prices are 500 quid which seems silly money to me.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    plr are press bent (narrower at the bends), the ashley ones dont fit.

    sayin ghtat, ashely offer a custom made setup for around £200, spose itll have to fit then.

    hmmm
    http://itsalmosttime.co.uk/blog/

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    i take it you are talking about systems now? i only see a problem in the manifold as systems have been made for years?

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    i found the ashley exhaust the easiest option

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust


    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    This is an exhaust manifold I made up for my mk2 Cortina. it started life as a piper RS1600i cvh manifold and its just cut up and rewelded to a home made zetec flange. Since the photos were taken I have fitted the 2 1/4" tailpipe and the lambda sensor fitting in the last collecter.
    The rest of the systems a 2 box 2" ashley which is mucn too noisy and i am looking for something a bit quieter in 2 1/4.




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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    The PLR 2 1/4 xflow system is cheap and a lot quieter than Ashley exhausts. You will need a joining sleeve to connect it to your manifold though

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Thanks for info, do you have a contact/supplier for this system. I have a flexible pipe section between manifold and system so joining it all up will be easy.

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    http://www.peterlloydrallying.co.uk/ they are a site sponsor so if you mention the site you can get free delivery I believe

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Thanks Peter Lloyd Rallying PLR obvious really (brains doing a post 40 slowdown). Cheers

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    Re: HOW TO FIT A ZETEC - Part 2 - Exhaust

    Some of you will have seen on the other RWD Manifold post that we are doing this one at £245+VAT as an introductory offer


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