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Old 08-15-2006, 02:38 PM   #61
phord_phocus86
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Well, would putting the cat behind the flex be a problem?
I'm assuming if people use race headers to delete the cat that our flex pipe is ok without a cat in front of it.

So we need to find out how the ZX3 catback works, when fitting it to a sedan do you add the extension before the muffler, or after? I'll try and find out. Hopefuly it's before the muffler.
If it is before the muffler we can move our cat behind the flex pipe. I'm not exactly how long out cat is, but I'm guessing with flanges on both sides it will be just under a foot? so maybe the ZX3 cat back will fit perfectly, but maybe even the ZX3 cat back will be too long, so any cat back system will have to get chopped shorter, and most places the zx3 is cheaper than the sedan.

so yeah.

new questions are now-

Can the cat go behind the flex? (legally and safely without causing any harm)

How long is our cat-converter?

Where does the ZX3 cat-back system need to be extended to fit a sedan?
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Old 08-15-2006, 09:29 PM   #62
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wow good info, i will wait til you guys figure it out seems like it could work, i do have a custom made flex for the spi from tin_maddog so im not sure on how the flanges(parts that connect to the end of the piping, right?)work with that header
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Old 08-16-2006, 07:40 AM   #63
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^^ yeh if you wanted to use that flex you'll have to put a new flange on that or put a focus one on the escort header.

I'm going to try doing this but it won't be until I can afford the whole she-bang.

I think I'm going to wait till I've saved up about a thousand just to be safe. Then use the extra to either start buying parts for a mmanual swap or for tuning.
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Old 08-16-2006, 10:25 AM   #64
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yeah I didn't think about getting a focus flange off our manifold, and welding it onto the escort header ... then maybe it would just line-up alright with the cat? who am I kidding ... sounds too easy!
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Old 08-16-2006, 11:49 AM   #65
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first off our cat is inside the engine bay not under the car, and welded to the cat on the back side is about 3 feet of bent pipe befor it connects to the flex pipe which starts by the front wheels and goes up and through a bunch of junk then back down to connect to the "cat-back" system which in out case is truely a Flex-Back system.

and if you look at the escort header we would use, it is a long pipe design and goes straight past where our cat is, so to just bolt right up to our cat you would have to chop up the tail end of your cat plus the new header plus your old manifold which I don't think you can do.

there are two simple ways to go about this (assuming you can put the Cat after the flex pipe)

1) put an escort flange on our stock flex pipe to connect to the escort header, cut off both sides of the cat-converter and put on the flange that connected the muffler to the flex pipe on the front of the cat, and get a donoy flex pipe from any zetec or SPI focus and cut off the back flange and put that to the back of your old cat which is now after the flex pipe, so you can bolt up any cat-back system and actually have a cat-back system (but you will have to cut off a few inches of it before the muffler, maybe not if you get the zx3)

2) put the flange from the back of our cat onto the escort header to bolt up to our flex pipe, put the flange from our muffler to the front of the cat and use a focus donor flex pipe as the flange on the back of the cat, to bolt up to any cat-back system (again you would have to cut off some ammount for it to fit, maybe not if you get the zx3)


There is one other solution, but I'm not sure it would work, it's just an idea that poped into my head just now-
-cut off both ends of the cat so it's straight (or just buy a new universal one)
-cut the new heder right after the third collecter (when it is just one pipe)
-weld the cat on
-weld the flange from the end of the cat on right after the car to eliminate the un necessary bends and to bolt diretly to the flex and back

^^^come to think of it this IS the easiest of the solutions, but it's a clearence issue now, hopefully there is enough room from the third collector to the flex pipe to fit a cat, then hopefully it won't scrape the ground on lowered cars.

*If and when I eventually do try to put escort headers on I'm going to do this last version, it sounds like the best solution to me, and if I get an aftremarket universal cat, I can get a round one and hopefully shorter so it will fit and allow for more clearence!

wow, Playa, you keep me thinking! keep finding problems with it make sure I'm not forgetting anything
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Old 08-16-2006, 12:05 PM   #66
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... also update original post because it seems the information I gave out based on my reasearch and guessing has been proven wrong.

now all we need is a guine pig to test out fitment and rearrangement of the cat/test. if no one will step up to it, I will hopefully have the money for it after the holiday season
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Old 08-16-2006, 12:17 PM   #67
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we're coming along well ... i'll go take some looks around on our engine (i'm installing new goodies today abnyway) and add to our hypothesis later tonight ... so far it seems as if your last idea is our best : )
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Old 08-16-2006, 03:10 PM   #68
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You will need to have more than just a mating flange between the flex and the Escort header. The Escort header exit points in a different direction than the flex entry so you need an extension or bend to get the header to match up with the flex.

If you could see them from the side the header flange is perpendicular to the ground while the flex sits 6 inches (guess) away from it at an angle facing towards the bottom front of the car at about a 45* angle (another guess).

There is plenty of pipe between the muffler and flex to put a converter in-line after the flex. This should be do-able provided the heat doesn't bother the underside there and you extend your downstream sensor wires....oh, and you'll need a sensor bung welded after the converter too.

Recap:

To install an Escort header you only need a custom piece of pipe to go from the end of the header to the flex. A muffler place will be able to make this for you and they will have the flanges they need.

To add a converter after the flex, find the narrowest, shortest converter you can, take it to a muffler shop and tell them you need it where that long pipe is, with a sensor bung after it. Again, they will have the flanges they need. After that, just get a longer sensor harness and viola!

You will still have a restriction from your OEM flex pipe though. To get a higher flowing flex it is another custom deal.
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Old 08-16-2006, 06:39 PM   #69
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you could also just chop off the end of the header as short as possible put in a cat with a bung before it and get custom piping to connect to the flex and back.

so you wont have to extend that far, but replacing the cat would be a PITA.

so on second thought focus newb you're right with putting it after the flex. the only thing is we don't know for 100% sure that the flex will be able to survive without the cat in front of it.
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Old 08-16-2006, 07:50 PM   #70
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CHECK THIS OUT ! !

eBay Item # : 160019605116

Ford 2.0L Long Tube Header!

Fit, no fit?

oh yeah; dibs!
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