Escort Sigma 1600 Race Car

[Roadsport]

Re: Race Escort Zetec SE (engine build)

One down (almost, still need to turn it left a little to align with the exhaust pipe) three to go.
The position of the collector is not ideal as sits a bit below the x-member level and is the lowest point of the car .
So I need to stay between the white lines (little more) from now on...

[Dazzabhoy]

Re: Race Escort Zetec SE (engine build)

looking good mate, this is always a cracking thread to read

[Roadsport]

Re: Race Escort Zetec SE (engine build)

looking good mate, this is always a cracking thread to read

Thanks D. I'm pleased with the progress too. So far.

[Tristan]

Re: Race Escort Zetec SE (engine build)

There's so much time measuring and tweaking and thinking in exhausts isn't there? I made a few and you would just wonder where the hours go..

[Roadsport]

Re: Race Escort Zetec SE (engine build)

There's so much time measuring and tweaking and thinking in exhausts isn't there? I made a few and you would just wonder where the hours go..

So far the exhaust system has gone fluently. But I've now only done the easy bits.
The following three primary pipes should be more challenging.

This project has been the most time consuming build yet. There are now off the self solutions for this one so very much customisation needed. Luckily most of the engine parts were available on order or off the shelf.

[Roadsport]

DIY mani

Got the second primary pipe done today. This one was not fluent in any way. The first version came out too short and went to the bin.
Now the manifold is starting to take shape so I hope the third one can be assembled on the floor rather than in the engine bay. Easier on the back if nothing else.

[Roadsport]

Re: DIY mani

Third done.
Was faster to make than the second since it could be assembled in the bench.

[4drmatt]

Re: DIY mani

good stuff. that looks very neat

[dobuy]

Re: DIY mani

great job, looks brilliant

[Roadsport]

Re: DIY mani

Thanks guys!
I really hope it works propperly too.

[Tristan]

Re: DIY mani

Top notch . How are the lenghts working out evenly for you? Where'd you get the funky looking extractor?

a cylinder head question now... what was the standard Ford ports like? nice shape , smooth and with a nice transition to the valve seats , or were they badly finished?

[Roadsport]

Re: DIY mani

Top notch . How are the lenghts working out evenly for you? Where'd you get the funky looking extractor?

a cylinder head question now... what was the standard Ford ports like? nice shape , smooth and with a nice transition to the valve seats , or were they badly finished?

Getting them even is the tricky part. But now the three pipes are all within 5mm from each other. So close enought for me.
Can't really be absolutely sure about the lenghts and differences of the primaries since it's quite tricky measuring them 100% accuratelly. But the little stubs welded on the flange allow me to fine tune the lenghts a little. After all the pipes are done. If I need a pipe to be longer I'll just slide a spacer ring between the primary pipe and a flange. A little like I did with the third pipe.
Also made sure the primaries all run straight for about 10cm or so before they go in to the collector. This allows me to shorten the primaries If needed in the RR session.



It is a custom made extractor for this set up. I've had it made cause that's the bit I can't do myself.

The ports are fairly good. Most of the work needs to be done around the valve seat area and the seat itself. I guess the ports mainly need cleanig up a bit. Not sure tough I'm not an expert come to cylinder head modifying. I had my headmodified by an expert. You can retain original valves and tappets for up to very high stage of tune.

[Tristan]

Re: DIY mani

Thats very clever thinking leavin all the pipes straight before the extractor.

[Roadsport]

Re: DIY mani

That clever idea got a minor set back today as I made the fourth pirimary pipe. The final tube could not be made with the 10 cm straight section. The pipe would have been too long and the bend would have been too tight . The straight section is only 7 cm on this final one. So that leaves me the possibility to shorten the manifold by 5cm without much effort.

[Roadsport]

Re: DIY mani

It's now done. For now. Or atleast I thought it was.
Learned today that I had made the measurements all wrong. I had misunderstood the starting and the ending points. So now I need to modify the manifold a whole 7(ish)cm shorter
But I guess that's what happens when you don't know what you are doing.
And after all its only a little nip and tuk job before I get the seams TIG welded.