Ford Fiesta ST
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#561874 - 16/05/17 06:04 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
pyle Offline
n00b

Registered: 04/09/16
Posts: 36
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.

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#561882 - 17/05/17 04:17 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
_Jimmy_ Offline
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Registered: 11/02/14
Posts: 1197
Loc: Northwest
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...
_________________________
2005 Fiesta ST
Milltek non-res, Newman fast road cams, Fusion Fabs custom inlet manifold

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#562092 - 10/08/17 10:20 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
RallyLAD Offline
n00b

Registered: 06/09/16
Posts: 9
Loc: Denmark
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

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#562093 - 11/08/17 08:31 AM Re: Fabricated Inlet Manifold - Group Buy [Re: RallyLAD]
_Jimmy_ Offline
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Registered: 11/02/14
Posts: 1197
Loc: Northwest
Originally Posted By: RallyLAD
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.
_________________________
2005 Fiesta ST
Milltek non-res, Newman fast road cams, Fusion Fabs custom inlet manifold

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#562094 - 11/08/17 03:26 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
RallyLAD Offline
n00b

Registered: 06/09/16
Posts: 9
Loc: Denmark
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.

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#562096 - 11/08/17 05:04 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
YellowBadge Offline
MountooningTipster

Registered: 26/08/07
Posts: 11369
Loc: here
good work on this project performance looks good.
_________________________

MR200 Stage 3 200PS
Evans Halshaw
Mountune Pro

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#562108 - 13/08/17 10:35 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
kenny Offline



Registered: 08/03/08
Posts: 11596
Loc: essex
Does look good

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#562616 - 04/06/18 05:06 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
M@ikel Offline
n00b

Registered: 04/06/18
Posts: 8
Loc: Belgium
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!

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#562619 - 08/06/18 01:38 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
YellowBadge Offline
MountooningTipster

Registered: 26/08/07
Posts: 11369
Loc: here
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.
_________________________

MR200 Stage 3 200PS
Evans Halshaw
Mountune Pro

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#562623 - 11/06/18 08:14 PM Re: Fabricated Inlet Manifold - Group Buy [Re: YellowBadge]
M@ikel Offline
n00b

Registered: 04/06/18
Posts: 8
Loc: Belgium
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?

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#562624 - 13/06/18 06:26 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
_Jimmy_ Offline
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Registered: 11/02/14
Posts: 1197
Loc: Northwest
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.
_________________________
2005 Fiesta ST
Milltek non-res, Newman fast road cams, Fusion Fabs custom inlet manifold

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#562625 - 13/06/18 09:43 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
M@ikel Offline
n00b

Registered: 04/06/18
Posts: 8
Loc: Belgium
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?

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#562626 - 14/06/18 03:36 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
_Jimmy_ Offline
Site Supporter

Registered: 11/02/14
Posts: 1197
Loc: Northwest
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.
_________________________
2005 Fiesta ST
Milltek non-res, Newman fast road cams, Fusion Fabs custom inlet manifold

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#562627 - 14/06/18 05:32 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
M@ikel Offline
n00b

Registered: 04/06/18
Posts: 8
Loc: Belgium
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!

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#562628 - 14/06/18 11:04 PM Re: Fabricated Inlet Manifold - Group Buy [Re: _Jimmy_]
_Jimmy_ Offline
Site Supporter

Registered: 11/02/14
Posts: 1197
Loc: Northwest
_________________________
2005 Fiesta ST
Milltek non-res, Newman fast road cams, Fusion Fabs custom inlet manifold

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