You'll find making an intake manifold will be a little harder than it looks.

You'll have a TMAP sensor that you'll need to mount. Since you have a 2009, you don't have to worry about an IAC. The ECU will need to be reflashed or your will have to leave components hanging for the IMRC control mechanisms or just deal with a constant CEL.

On a simple single runner manifold design, I don't think vacuum line placement varies much; where ever is more convienent to fabricate.

 

You actually can just "notch" the cosworth one to make it fit. You don't have to move the power steering resevoir. This is indicated on FSWerks site. But either way, good luck man.

 

EGZ. I'm not fully sure what you mean about the IMRC issues.

 

hes saying if you don't have a tune, the car won't run right. you would need this for either your own, or any new IM (other than stock). i am not sure, but i believe it is b/c you change the volume of air?

 

EGZ is talking about the vacuum and electronic bits that control the variable length runners on the stock manifold. You can plug them off and leave them hanging in the engine bay, or remove them and get a CEL.

You'll want to tune regardless for a new intake manifold.

 

just out of curiosity have you done any other modifications to your car. Changing out your intake manifold without some extensive modifications to your engine(turbo or engine build) is kind of useless. Most peeps dont even bother with an intake manifold unless they are pushing some serious boost and in all honesty, Ive seen many dynos for the Duratac and there isnt really much to be had with another manifold. You lose a lot of low end torque. Take a look at Focus Sports website and look at the dynos, you will see what I am talking about.

 

Making a one off intake manifold is great and all, but you'll end up sacrificing SOMETHING. I seriously doubt that a new manifold for the duratec would end up being a win win. Just look at the cosworth, sure it pops out great numbers on the hp side, but the torque is eh. Sure it's "flat" but that doesn't make it any better than a much higher lumpy number. Also if you build it right you should be able to make a flat torque curve anyway without a new manifold.

 

My car will have stage 2 cams, intake, exhaust, header, and possibly some head work. Your saying with this intake there is no power to be made? Also I have found formulas as to how long the runners need to be to make power in a certain area.

 

Yeah but it won't have the adjustable tumble flaps which help the bottom end, which I personally like. Even if you had a book on formulas for making horsepower doesn't mean you will. Every engine is different and reacts differently. Your money is better spent on other things, since it'll end up costing you twice as much as the cosworth and with quite possibly fewer gains.

 

making your own manifold from scratch is easier than retrofitting the old power steering stuff on your 09?

some how... now dont quote me... im not a rocket scientist, but to me... just swapping parts seems quite a bit easier than re-designing the intake...

 

also, your discussing stage 2 cams... what cams? what is the purpose of this build? stage 2 cams wouldnt require a new manifold... stage 3+'s and above you would want to start thinking of a new intake manifold system...

 

I thought these mods would benefit from a manifold. From what it sounds like it wont. I'm now reconsidering the idea.

 

ask warneej. he has the cosworth, and has not had a ton of engine mods, and kenzx3 too i think.

 

I tried to post yesterday but idk it was messed up.

Anyways, where are you getting your information from Boosta? I made a buttload of power NA with my setup. As did Egz and he is more built that I am.

Wouldn't this manifold outflow the head by far? I know on the 2.3L the stock manifold is the bottleneck but not sure how much less the 2.0L head flows.

Next you don't sacrifice anything, the car has more power everywhere, I keep telling people this to debunk the naysayers that haven't ever run one. It just happens to have a TON more up top, because of the flat torque curve.

Flat torque curve equals a diagonal hp curve.

Its a cool idea and it'd be fun to fabricate however I don't know if it would be cost effective in comparison to the Cosworth.

 

I had a fairly flat torque curve without the intake manifold and 156 tq, same as egz without the extra work I've done now. I should when all is said and done I should have around 166 or more than that for tq. So yes you do lose some torque. There is no win win for intake manifolds, not in my experience on other engines (there may be exceptions but the cosworth doesn't seem to be one). Not saying the cosworth is a bust, it's probably the best intake manifold you can get or ever will for the duratec. But it's not the best mod everyone.

 

^^ Thanks. I'm going to continue looking into it to see how much its going to cost and such.

 

Unless your head outflows the intake then theres really no true gain to be had.

Its just like buying an "X" brand head because they claim it flows 900000cfm @.5 lift... which is great but theres no cams that make that much lift, then you see the intake wont support it, or the maf wont support it, or the TB.... the list goes on and on.

I would step back and see how the car runs after cams are installed then take a long hard look and figure out where your next restriction is then work from there.

 

Unless your head outflows the intake then theres really no true gain to be had.

The 2.3L head outflows its manifold by quite a bit and I think its true for the 2.0L as well.

But I disagree with you NAD, I feel its one of the single best modifications for the Duratec engine albeit on of the more expensive ones.

 

I'd like to do a dyno before and after when my engine is complete. Just to see exactly what it does. Although it'd be convenient to compare my results to egz since the builds are ALMOST identical. Just with different tuners,tad bit of headwork, and no cosworth IM.

 

You need a thread similar to tb1999's.

I'd like to see step by step on yours as well.

 

Probably when all is said and done and I don't lose any fingers I'll probably set up a little site as it'd be alot easier to lay everything out in an informative manner that way, not to take anything away from tbs thread. Or this forum, just think it would help more people understand a few basics that may not be working on a focus or visit message boards.

 

so OP, you are doing this then? how do you even do it? i mean, do you go out and buy a block of metal and start cutting? or do they have a base to start with somewhere?

 

Well I drew up basic plans in unigraphics a cad program. I have the over all design. I just need to get a piece of aluminum cnc'd and the get tubing for the runners and tig weld up the overall body. I feel like I have a pretty good overall design for airflow. Based on the researching I have done I should get the best power around 5,500-6,000rpm.

 

Keep us posted along the way.

 

so that is what you do then...you get a big block, draw it up, and have it done at a cnc shop?

 

researching on what? as far as i know... no one has really custom made a manifold for the duratec motor... so i would like to see where this research comes from...

 

There are plenty of sources out there that give formulas for sizing various components of the intake manifold. Things like runner length, cross section area, and plenum volume are all available in many sources.

However, since the focus has no adjustment to the cams as an option (such as Vtec etc.), you are really stuck with having to design for a specific rpm for peak gains.

But, running through all the formulas, you should be able to get close for plenum volume and sizing, and intake runner cross section area. I'd think that the best route after that would be to make a set up where you can do dyno testing with adjustable runner lengths to determine what the optimum size is for the rpm range you want to run at.

 

Lets keep this on topic guys.

 

Honhon, u drive a better car then a Focus? ROFLMFAO!!! Who u trying to fool.

 

Because a Focus is such an awesome car, right? [rolleyes]