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Old 07-24-2007, 09:29 AM   #11
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wow... you spent a LOT of time on this... you must got some patience. great job man

keep us updated.
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Old 07-24-2007, 09:45 AM   #12
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great write up so far, I'm getting excited to start mine this fall . luckily I have a zetec though so routing the exhaust & int. cooler pipes will be a little easyer. glad your posting over here, i'm here more often then tc.com!
ya got some mad welding skill going on there too, well done.
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Old 07-24-2007, 11:34 AM   #13
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Omg I dont even know what to say. Good luck though.
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Old 07-24-2007, 12:18 PM   #14
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very nice looking project, good luck on it and keep us updated

what size maf housing did you say you were looking for? if you are looking for 2.5 you could use a ebay intake for the maf pipe. that is what i did and they are pretty cheap.
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Old 07-24-2007, 12:27 PM   #15
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I could fairly easily make a new, larger MAF housing, but my tuner recommended using the stock MAF housing and a Diablosport MAFia so that's what I'm doing.
I know other tuners use a larger MAF housing, but I'm doing what my tuner recommends.
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Old 07-24-2007, 07:31 PM   #16
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yeah 2.5 is fine. the reason a 3" is used is to extend the range of the maf. but unless you plan on making a lot of power there isnt any need for it.
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Old 07-24-2007, 09:48 PM   #17
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Day 8

Start time: ~6:45pm
End time: ~10:15pm

Today was another short weekday.
I cleaned and painted my oil catch can.
It was originally chromed, but I personally don't like chrome and it didn't match anything under the hood and stood out like crazy.
I ground off any loose chrome and cleaned it using mineral spirits.
I painted it satin black, which shouldn't really stand out but look nice.

I mounted my MAFia to the battery tray with velcro.
Part of that is so it can be removed to adjust when necessary, and I may go to a lightweight battery later on so no need to permanently mount it to the battery tray.

I installed the 55lb injectors.
Aside from having to huff a lot of gas fumes, this was one of the easiest things I've done so far.
Two 10mm bolts hold in the fuel rail.
Each injectors has a small metal clip that easily pops off using 2 flat head screwdrivers.
That metal clip goes on the new injectors.

I also removed all the stock spark plugs and coated the threads with anti-sieze and then reinstalled them.
I don't want any suprises when I go to get my car tuned, and siezed spark plugs definitely fit that category!
I gapped the Autolite 103 plugs to .035" and set them in the passenger seat so I won't forget them when I go to get my car tuned.

Finally tonight I installed one of the -3AN reusable, swivel hose ends to my oil feed line.
I then ran a test route for the line, screwing the one mounted hose end to the oil sending unit.
This way I can get a clear idea of how much line I have to trim from the 6' section it comes in.
I'll install the other hose end after I trim of the excess.

PICS

Catch can before painting:


Catch can after painting:


Autolite copper plugs gapped at .035"


Stock injectors:


55lb vs stock injectors:


55lb injectors installed with wire adapters:
The 55lb injectors have a plug that works for the Zetec, but requires and adapter for the Duratec.


Oil feed line:
Blurry pic of the day.
Directions on how the hose ends are installed: Aeroquip reusable hose end pdf

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Old 07-25-2007, 11:21 AM   #18
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did you mig your manifold? And did you purge it at all with argon?
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Old 07-25-2007, 11:24 AM   #19
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Quote:
Originally Posted by cayres View Post
did you mig your manifold? And did you purge it at all with argon?
MIG, but all welds are with flux core wire. No gas.
I'm quite happy with the penetration even without gas.
There weren't any suprises. Everything is steel-steel and flows together nicely.
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Old 07-25-2007, 11:35 AM   #20
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Quote:
Originally Posted by cayres View Post
did you mig your manifold? And did you purge it at all with argon?
You only need to do that if you are welding a header made out of Stainless steel. No need to on mild steel.

Looks like a fun project, and looks good also!
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