I've been chatting with someone who's organising a group buy of fabricated inlet manifolds specifically for the mk6 ST.
I'm putting up this thread here so members of this forum have the opportunity to get hold of one if they wish.

Some background:
The company making it is called Fusion Fabrications http://www.fusionfabs.co.uk/
There is no affiliation with the company making these, the idea to have a manifold fabricated was driven by the rarity of the Mountune manifolds (the only other aftermarket manifold made specifically for a fwd 2.0L Duratec, no longer available new and twice the price of this for a used one), and the Cosworth/Pumaspeed design that results in a loss of low down torque and was intended for a larger engine. The idea for this has been thrown around a few times in the past but never lead to anything. This manifold was designed to suit the 2.0L and the runners were chosen to give good mid range torque, which resulted in something that looks pretty similar to the Mountune inlet (see below)

For best results you will need the supporting modifications such as fast road cams, full exhaust etc and a custom remap. We've been in touch with Dreamscience and they are working on a map to work with this manifold, this should be available once a test car had been to Dreamscience HQ to their dyno.

The 1st batch FF is looking to make is a minimum of 10 inlets @ £650 each. A 50% deposit will be required Payment will not be taken yet of course, the details are yet to be confirmed and there aren't any concrete dates yet because it depends on getting enough people involved. This isn't an off the shelf product; each one is made to order by hand.

If you are interested, please contact Fusion Fabrications via their facebook page (see http://www.facebook.com/fusionfabs/posts/1009875959118013) and let them know you are interested, but only if you are seriously looking to put down a deposit and buy one. Please also post on here so I can keep track of the numbers, for the 1st batch we are close to 10 already.

A Thermal Gasket will also be needed which will work out at £25 if we get 10+ orders for the inlet (usually £43.00 each outside of group buy) http://www.ferriday.co.uk/thermal-products/

Here are some details of testing quoted from another page. The prototype manifold was tested on a 2.3 which obviously isn't ideal but the main idea was to show the difference between the Cosworth style and the Fusion Fabs inlet. There are also some pics and a video of the sound.

bit loud

Yeah, he had the mic in the engine bay for the video though

ah right

They should do an exhaust manifold too!

They do make custom exhaust manifolds but there's already plenty off the shelf ones available

For inlets there's only really cosworth or a replica, unless you're lucky enough to find a mountune or go the difficult route and adapt a rwd layout caterham one (also fairly hard to come by). None of those are cheap either, pumaspeed cosworth replica is the cheapest at around £400, cosworth are almost £1000 and mountune ones are going for over £1000 if you can even find one.

What has always put me off the cosworth/pumaspeed ones is the short runners optimised for high engine speed but losing low and mid range torque on a NA engine.

here's the graphs for all three MT upgrades v standard car, although the 165 has more torque low down and is the best of them all, having had all four variants MR200 feels easily a match low down for 165, depends on gearing too, my MR200 will pull very hard from 3rd when just dawdling no need to drop to 2nd at all just pulls immediate. Think max torque is 210nm not sure.

What are these 3 MT upgrades you speak of and where can I find them? Mountunestore.com only sells a small amount of products for the MK6

The MP165 (exhaust/induction/remap) and MP185 (MP165 + cams/remap) can be done at certain Ford dealers or at Mountune HQ in Essex. The MR200 (MP185 + inlet mani/60mm TB/remap) is no longer available, best way to get it is buying another car with the kit already on.

That's where this manifold comes in as people want an inlet to go to the next stage, but there isn't a dedicated one for our engine on the market. Lots of people have the Cosworth style but it was designed around a 2.3 duratec and high rpm, the fabricated one will give better driveability on the road up to around 6500rpm

I'm not sure any of the Mk6 kits are still available, you can ask Mountune directly, all Mk7 kits now.

MP165 could be done at a Ford approved garage, MP185 and MR200 both need to be done at Mountune as they need the car or ECU.

I've had all three kits from brand new car I bought in 2007, I'm now on MR200.

We now have 8 buyers which Fusion Fabrications have said is enough for the group buy once the £300 deposits come through.

He's aiming to make up a batch of 5 by the end of April then start on a second batch, of 3 so far, but he will be buying enough material to make 10 overall if needed

Defo not worth the 650 asking price!

On what basis? It's priced on materials and fabrication time. In terms of performance its been designed to give better mid range torque than the other available alternatives, so worth it from that point of view imo.

It's given results much better in the mid range than the Cosworth inlet and people pay more than £600 for that, and it doesn't even work well on 2.0 NA engines (kills torque)..... but hey, it says Cosworth on it.

Anyway... they're being made at the moment so I'll be able to say if it was worth it some time soon, but I already know it will be given the reports from the two that have been made.

I'd be keen to hear about the results once you've fitted it, might pick one up if there's a second batch and the results are good. But it looks like a lot of work to put it in, relocate the battery etc. I wish I could find a mountune inlet for sale!

Turns out you don't have to relocate the battery if you connect the filter straight onto the TB

The Cosworth inlet's design is superb. The one thing allowed to affect the power curve is the cam timing. If one doesn't like the curves just alter the timing for high rpm or mid range. The exhaust and the inlet has to have as much flow as possible. These runners are too long and will make the car slower. The Peugeot 306 has an inlet of similar design to the Cosworth and if someone is going to design an aftermarket inlet take a look at that.

For high rpm you want short runners whereas the length of these was tuned to give peak torque around 5k rpm... for comparison it's a similar runner length to the Mountune inlet. As a result it plateaus at the top end giving a lower peak power, but gives bigger gains in the mid range that you use most of the time. This is always going to be the compromise with runner length tuning. We could have asked for shorter runners (it's custom after all) but that's not what was wanted.

The Cosworth is well designed for certain applications but the runners are much shorter so are optimized for high rpm (or forced induction), but how long do you spend up in that range in a road car? It was also designed for a 2.3 duratec, not 2.0.

Doesn't matter at this point as the group buy is done so those who wanted one are getting what we wanted, but the torque figures speak for themselves (Red is FF, blue is cossie)... more power until 6k rpm, but if you want a larger peak power figure get the Cosworth or Pumaspeed.


Not long to go...

So how are they performing on the different set-ups?
I didn't get a chance to take part in the group buy, but I'm
still thinking about buying one.

So let's see those dyno sheets and spec lists :-D

There's a guy selling his ST who hasn't fitted the inlet yet, so he's looking to sell it - I can put you in touch. FusionFabs can also make them to order individually now as they have made jigs.

The production inlets have slightly shorter runners than the prototype and better porting into the flange so have better top end.

There's two graphs from people so far but photobucket has eaten them, I'll ask for them to be put up again. Both were dynoed at Dreamscience and both running Newman ph2 cams (I'm pretty sure) and 60mm TB and a tweaked hyper R map. The first is running a RamAir filter behind the headlight, custom sport cat and Mountune catback, the second has a K+N directly on the TB (like mine is), plus decat with Milltek resonated cat back.
car 1. 190bhp @????rpm / 190lb.ft(257Nm) @????rpm
car 2. 205bhp @7000rpm / 180lb.ft(244Nm) @5000rpm

Here's the second one in blue compared against an MR200 in red (wasn't on the same dyno unfortunately), I know it's not the original plot but it's all I have at the moment with the others hidden by photobucket until I can retrieve them. I'll put my graph up once I get it done.


I recently fitted mine, getting it mapped today at DS and dynoed if the machine is available.
It feels a lot more urgent when you get on the throttle low down compared to just cams. Makes a great sound too, similar to how the MR200 growls.

Looking good!
Is this still on the 2 litre?

Yes please, I'd like the sellers info. I have been in contact with
FF but I don't mind buying second hand.

good work on this project performance looks good.

Does look good

Hello fellow ST-freaks,

first off all i want to thank the people making this FF inlet come to life!

I'm in contact with FF to buy one but was wondering if someone could help me out with the connections.

Matt told me there was a "breather connection" but that most people don't use this breather, however he wasn't exactly sure and told me to contact someone from the group buy to verify about which goes where. Is he reffering to the valve cover breather?

He also told me that i would need additional hardware (From Matt: vacuum hoses and fittings to connect to the inlet, in place of the two push fit connectors, and also the breather fitting on the underside (if you choose to use this one, some don't bother), could someone help me out with this please?

Thanks!

am not sure Jimmy above can help out on your question, also if I remember you might need either new or uprated engine mount as the manifold sits a bit high and can hit your underside bonnet as the engine moves under hard load. Otherwise great bit of kit for the money.

Thanks for the info. I think i've got it sorted out so normally it should go together without a problem.

Good thing i have Vibra Technics engine mounts and torque link on the way as well, together with an uprated clutch and Quaife ATB.

Where did you get this info about it hitting the bonnet? Is there another forum for this inlet? To bad this page has gone quiet, not much info on setups and numbers.

Planning to go with an standalone ECU (ECU Masters EMU Black) to get the mapping perfect, should run great with a custom GGR CAIS!

You say great bit of kit "for the money". The way i see it it makes more power than the Mountune inlet or am i looking at it wrong?

Hi, yes there's another thread on another forum. There's currently a second batch group buy underway.

We found that one runner is very close to the bonnet latch mechanism and will rub, so I have swapped to a vibra technics mount and grinded some meat off the latch to make room. Others have also adjusted the slam panel or fitted bonnet catches.

Fitting wise some people have reused the old hoses (Evap, servo and pcv), I changed mine to fuel hose and put a little filter direct to the pcv. Matt is referring to the pcv fiting on the manifold which most of us have blanked to avoid oil build up bit you could just reconnect a pcv hose.

You also need slightly longer bolts, a ferriday gasket is recommended and an air filter, the off the shelf GGR will not fit without some tweaking, I used a universal ram air filter straight on the TB.

Hello,

could you direct me to the other forum please? I know about the second group buy, i'm in it! ;-)

I'll keep an eye on the rubbing, thanks for the info that's very helpfull!

I've told Matt he doesn't need to put the pcv fitting on mine, less fabricating for him and no blanking for me.

Could you tell me the pcv size so i can order the correct K&N filter please? Is it the same size as the valve cover?

I'm also planning to change to different hoses for a clean look. So you used regular fuel hose? And what about additional parts to fit the hoses to the manifold?

The plan with the GGR is to mount it where the ECU is (i'm gonna try to mount the ECU against the battery box, shouldn't be to hard), this puts the airbox in the same location as on the MK7 FST and from there i will run a hose to the lower grill, still a very short way for the air to travel and it will be completely closed.

The only problem i'm having is that the GGR will be mounted solid so no movement is possible (unless you have a better idea?), should i use something different, more flexible than a 90° silicone bend between the throttle body and GGR? Or will the Vibra Technics take away enough engine movement?

The other site is fiestastoc.com

The fittings you need are all AN6, 10mm fuel hose for the evap and 8mm heater or silicone hose for the servo (would have used fuel hose but it was too stiff). I used 45 degree barbed fittings for neater routing.

Yes, the PCV and valve cover are the same, 16mm ID.

The vibra technics mount still allows quite a bit of movement if you get the road version. The race version probably a lot less so but then there will be too much nvh.

I've searched fiestastoc allready and can't seem to find a dedicated thread on it, could you send me a link please?

Since i need 2 different sizes of hose, do i also need 2 different sizes for the AN6 fittings?

I've searched after the AN6 fittings, first time i'm hearing about these, do you know a good place where i can get these from?

Routing on yours is very neat indeed, i'm hoping to achieve a similar result!

Thanks for the info!

Yes, two sizes of fitting, I used these

https://www.merlinmotorsport.co.uk/p/45-degree-hose-union-6jic-female-to-8mm-hef47-6-5

https://www.merlinmotorsport.co.uk/p/45-degree-hose-union-6jic-female-to-10mm-hef47-6

http://www.fiestastoc.com/forums/topic/305274-ff-inlet-manifold-round-2/
The thread might only be visible to paid members

thanks Jimmy

I think it makes more torque lower down but a bit less power, end of day all engines and sets up are different and will make random powers v other same set ups, I've no idea what mine makes all I know is, that is it is faster and pulls harder than previous MP165 and MP185, pulls well from very low speed in 2nd or 3rd when dawdling and seems to cope with similar cars of similar power either side of 200bhp when having a bit of traffic lights fun. So am very happy with it, should be 196bhp and 210nm but it wouldn't bother me if it made less than that on rollers, upset a new Golf GTI yesterday when I gapped him in 2nd at 7200rpm, he wasn't happy !!!

Haha that's great to hear, love these moments in our sublime little cars! Allready had a lot of fun with an M3, CLA AMG and a Mini JCW (193bhp), nog saying i was faster than the M3 and AMG but we had proper fun and both gave me a thumbs up afterwards AND i was faster than the Mini, it's my mate's and we did multiple runs so the Pumaspeed 190+ kit must be close to the claimed power.

Matt told me it would be OK to drive with the inlet without a remap for a while but that i would need to be carefull cause between 3- and 4000rpm it runs lean, is this with the original map or also with the Pumaspeed 190 map?

The reason i ask is that between installing the inlet and coming to the UK for a remap i need to install the GGR CAIS but since i need the ST this will be spread over multiple sessions (fabricating, measuring, ordering the needed parts, waiting for the ordered parts... ), so will it hurt the engine running without a dedicated remap or should i avoid running it?

I really don't know, I guess others may have done the same as you whilst awaiting mapping etc so best ask them or Jimmy, bottom line would be drive it but never thrash it or long drives at high speed, so urban 30mph would be fine and you would never go above 3000rpm anyway.

Mine was mapped for cams before I fitted the inlet, I ran it like that for a few months before having it mapped again, but didn't go over 5k and tried not to floor it, easier said than done though lol

Haha i get it, drive it like a baby untill i get the mapping sorted. And yeah, easier said then done indeed!

Great news, i've been in contact with the official ECU Masters distributor for Belgium and the Netherlands (JT Performance, situated in the Netherlands) and they are also able to do the same as Jamsport (EMU Black, plug & play, mounting, mapping) for the same price as Jamsport so that saves me a trip to the UK.

If everything goes well it should be done in September.

Thanks again for all the info, you guys have been very helpfull!

Another question for the experts:

Which size throttle body should i use? I'm currentle running the original and have the 60mm ready to go.

Matt told me the inlet is designed around the original TB but i noticed that the few mapped cars being discussed here run the 60mm TB.

And since Mountune uses the 60mm TB with there inlet and the FF inlet is designed around the MT inlet i'm kinda confused.

Most of us are using a 60mm but I don't think it's necessary, I can't tell any difference between the two.

Ok thx. I'll mount the original and maybe take the 60mm with me when they are going to install the EMU Black, since it's live mapping it should be easy and interesting to test the difference between them.

I am about ready to pull the trigger on an FF Inlet for my ST150 and later would follow the stage 2 Newman cams + map.

I have read just about every thread on various sites regarding this upgrade and asked around for information on the other parts that I would need to get this going. The feed back suggested there was a "shopping list of parts" on this forum? I can't find it and not for the want in trying....

So I would be very grateful if any of you guys that have completed this mod could reply with an idiots guide parts list and where to buy it all from.

Can you also tell me what I do with the PCV hose after the new intake is fitted?

I don't have EGR so no worries on that one or?

I have seen photos of various members cars some with new hoses and some with the original left on what's the advantages/disadvantages replacing or leaving?

There is advice to change an engine mount, what did you all go with for this?

pro's/cons of 55 - 60 throttle body?

Best air filter to fit the limited space?

If I've missed anything let me know?

and finally….. Once I have purchased all this lovely stuff would one of you come round, fit it all for me GRATIS whilst I talk crap and make tea???
TIA Gary

I got the FF manifold + map fitted by Jamsport on and it totally transforms the car in the low to mid rev range. However she only made 185bhp on the dyno, when might have expected 192 to 195 with a mountune 185, but probably needs a service and higher octane fuel.

Here are some photos - before - after - dyno test
https://hosting.photobucket.com/images/ah149/steveb_de/IMG_20201019_153658_8.jpg

https://hosting.photobucket.com/images/ah149/steveb_de/IMG_20201023_155914_5.jpg

https://hosting.photobucket.com/images/ah149/steveb_de/fiesta_st_dyno.mp4

Interesting! Did you have cams fitted as well? What torque did it make and have you got a printout?

Mountune provided Piper cams and valve Springs - fitted years ago.
Here is the video:
https://www.youtube.com/watch?v=DDO1WcQ0GCY&feature=youtu.be

The car made 183bhp (not 185), torque 158ib-ft(214nm). So as well as better fuel, may need checks on valve clearances.
Here is the dyno printout:
https://hosting.photobucket.com/images/ah149/steveb_de/fiesta_st_dyno.jpeg

https://hosting.photobucket.com/albums/ah149/steveb_de/cars/fiesta%20st/IMG_1140_zpsp61vtimk.jpg

https://hosting.photobucket.com/albums/ah149/steveb_de/cars/fiesta%20st/IMG_1138_zpsrhdgqkak.jpg

I think the thing is yours drops off quite quickly after the peak @6500.
The graph of mine from DS gives 190bhp @6500 but carries on climbing to 203bhp @7200, I dont know why it would be different though

Hi Jimmy, thanks for that comparison, so tells me what to aim for.
Maybe the Newman cams are better.

But the mid range is a vast improvement.
https://www.youtube.com/watch?v=3dzQHrgUP2c

Of course I reduced speed at end.

What is better for fast road daily, MR200 or this FF?
I am checking the group buy of MR200 but this FF looks much better in torque and that should be better for road. Also the price for MR200 is going to be crazy and now when UK is out of EU...

Thx for help

I'm not sure tbh. You could always come over for a holiday and return with it in your hand luggage hah

It would be cheapest option

I am waitung if FF will write back about price.