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Discussion Starter #1
We have recently finished prototyping a large plenum sheet metal intake manifold for the Zetec Ford Focus. It uses the lower SVT intake and our upper aluminum plenum.

The design was made with higher RPMs in-mind. It basically shifts the torque higher, which in turn carries your hp much higher in the RPM range.





Dyno comparisons of a 2000 Model Intake Manifold vs ours on a stock engine automatic car equipped with our street turbo kit, both runs at same boost:





Video of dyno runs can be found by clicking here.

Production pieces should be ready to ship within a week. The production version will come powdercoated texture black, but can be special ordered bare aluminum or other colors.

Pricing is as follows:
Upper Intake Manifold: $395.95
IAC Provisons: $39.95
SVT Lower Intake Manifold: $99.95
Upgraded Silicon Couplers and T-Bolts: $35.95
 

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Will you guys be making one that is all aluminum?
 

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what do the "IAC Provisions" consist of?
 

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Discussion Starter #6
As some of you are aware of, we are now producing two new intake manifolds for the zetec platform. We have a long runner small plenum and a short runner large plenum version. Both use SVT lower intake manifolds. We have recently done testing of both on a stock motor turbocharged automatic vehicle and have come up with some interesting results.

After testing both manifolds against the stock year 2000 intake manifold. For 90% of customers the longer runner smaller plenum manifold will be a better match. Basically the longer runner manifold produces more lower RPM torque and still makes within 10hp at 7000 RPM. If you plan on turning more than 7K RPM the shorter runner large plenum is more suited for you. Both manifolds offer a significant gain over stock even on this very mild turbo build. We expect to see much larger gains on higher hp engines.

In the near future we will be testing these on other motor configurations.

Y2K VS LONG RUNNER:







Y2K VS SHORT RUNNER:







SHORT RUNNER VS LONG RUNNER:







LONG RUNNER PICTURES:




SHORT RUNNER PICTURES:




All tests where done on a stock engine with a our turbo kit.
 

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Will this be an option for the SVT guys?
 

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You guys may want to do a couple weeks "field testing" that before putting it out there for sale.

We did some sheet metal intake manifolds early on and we found out that they flex way too much and after a couple of weeks all of the flexing would just destroy the welds.

It did make more power and TQ than the stock SVT manifold but they just couldnt cope with the pressure changes....... just something you may want to consider.
 

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You guys may want to do a couple weeks "field testing" that before putting it out there for sale.

We did some sheet metal intake manifolds early on and we found out that they flex way too much and after a couple of weeks all of the flexing would just destroy the welds.

It did make more power and TQ than the stock SVT manifold but they just couldnt cope with the pressure changes....... just something you may want to consider.
All depends on how thick the material is and how the made the joints.
 

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All depends on how thick the material is and how the made the joints.
True. I'll be interested to see how this holds up as well though.

TopSpeed, what kind of material did you use? How thick is it? And do you think it's capable of holding up to 30 psi over and over again?
 

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Discussion Starter #13
Our manifold is not made of "sheet metal" it is actually 1/8" plate with a 1/2" Plate base and throttle body flange. We guarantee it will hold up to any amount of boost pressure any one is running PERIOD....It comes with a lifetime warranty against cracking, just like our turbo manifolds. If you are having failures with an aluminum manifold then there is obviously an issue with the construction.
 

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Will this be an option for the SVT guys?

Does this manifold make the IMRC obsolete?
 

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Our manifold is not made of "sheet metal" it is actually 1/8" plate with a 1/2" Plate base and throttle body flange. We guarantee it will hold up to any amount of boost pressure any one is running PERIOD....It comes with a lifetime warranty against cracking, just like our turbo manifolds. If you are having failures with an aluminum manifold then there is obviously an issue with the construction.

Good to know. I'll be contacting you soon.
 

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I would first like to see testing done on some N/A foci...

or this only for FI applications?

Also what TB configuration would it use? SVT or normal zetec?
 

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Discussion Starter #18
So, many people have been asking, so we decided to remove the turbo kit off of the black car for a few days. So far we have installed our Race IM, we have not tested the other one yet. Here are the numbers so far:

HP:

TQ:


I would say that this is a pretty large improvement. I think we will get better numbers, we only got a few pulls in and the tune could improve.
 

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^^Hhmmm, wanna see more testing on a more bolt on n/a motor 5 speed, though from the looks, it looks like it broaden the power curves more.

I also have a another question. I thought the SVTF intake manifold doesn't line up strait with stock zetec head? What are you doing to correct this misalignment issue?
 
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