Intake manifold ?

[rangergt]

I have a cosworth knock off intake manifold for a duratec focus that I will be trying to modify to fit a ranger. I don't like buying knock off products but it's a lot cheaper so if it doesn't work out I'm not out as much $$. If all works out then I'll buy a real cosworth to duplicate, I really want that little plate that says "powered by cosworth".

My plan is to basically put the throttle body on the proper end (focus guys are backwards:moon:). I want to try and mirror the intake so that when I modify it, it still works the way cosworth engineered it to.

I will make it so it fits both my GT and `07 then I will be able to do some comparison to the intake manifold I fabricated (for the GT)in both mild and wild setups.

This project won`t happen right away as I need a running truck first :D. Here are some pics of what I'm starting with

[Foolee]

Sweet keep us posted, that's a pretty good knock off.

[fordnut71]

for a knock off its a good casting,a lil bit of grinding an it would prob give the real thing a good run

[Pierre]

where did you get the manifold from please reply

[rangergt]

I got it from CFM (central florida motorsports)http://www.c-f-m.com/index.php. In fact I have gotten most of my engine parts through them. They are a great company to deal with.

Not sure what your using the manifold on but be aware it requires a thorough cleaning before using as it still has sand inside it from the casting process.

[Pierre]

how much was the intake

[rangergt]

$400 plus shipping.

[rangergt]

If I can find the time this project may get started. I've been planning on starting it but I just got a heavy roof job on a mustang, his hood flew
off at the drag strip and smacked the roof up pretty bad so I'll have to get that job out of the way first.

[Skyy_4life]

for being a knock off, that things looks like its made with quality.

[rangergt]

Well it's ok but if i wasn't just cutting it up to see how it works out I'd personally buy the cosworth manifold. The casting isn't perfect or as nice as the cosworth and we'll see what kind of quality it is when I weld it up after modifying it, I'll bet it's a dirty casting.

[rangergt]

Ok so this project is now underway. I don't have a timeline for completion but at least it's begun. I cut the "backwards plenum" off so I can mount the throttle body on the correct end at least for a ranger anyway.

I have two goals for this project, first is to compare it to my fabricated intake (I predict my intake will outperform the cosworth in the lower end but the cosworth will shine on the top, we`ll see what happens). The second goal is to be able to bolt this intake on my `07 dtec ranger, it`ll require a turbo or a little more than stock engine to utilize the performance potential.

Originally my plan was to mirror the intake but packaging require a change in that plan. I will duplicate the plenum volume and try to locate the throttle body as best I can to mimick the airflow of the original intake.

Here`s some pics, the sectioned intake shows how dirty this knock off is inside. It still has the remnants off the casting sand.

[fordnut71]

wow that really is a dirty intake. i wonder how many buy this intake an just bolt it on an go.

[splatranger95]

Ya that needs some cleaning. It looks nice on the outside though!
I dtec build looks fun I must say.

[Ron83ranger]

that goes to show, when you get any new or used part for an engine it should be cleaned thoroughly. you never know what was left behind.
looks good though, im very interested in seeing what your truck makes. kick ass build.

[rangergt]

Well I have decided that I will have to change the location of the throttle body. So the plan is build the plenum with the same volume as the original and the throttle body will have to be located best for packaging. I have figured out a way to make this manifold so it is a direct bolt in for a duratec ranger and that is one thing I will try out.

[rangergt]

I forgot to add I have a plan for another intake manifold that would be fairly inexpensive and reasonablely easy for DIYer to put together with minimal welding. So if someone wasn't able to weld aluminum their self, it would only require minimum welding by a welding shop so the cost wouldn't be to bad. When I get the parts I'll start a thread on it.

[rangergt]

I've been jigging up the intake manifold and to locate the throttle body in the stock location but I don't really like the way it works out. So the plan is to locate the throttle body in a position that lends itself to be the most effective. This will require some minor modifications and relocation to hoses and such nothing out of the ordinary for this type of swap. It'll also require a new air inlet tube, again no big deal but when I'm complete it'll be a bolt on with minor mods:yesnod:.

[jsv578]

I also didn't like the way it comming out with the stock TB location
here some option I'm thinking right now.
straigh short runner, 20+70 deg:3"rad, 4"rad and 5"rad with a tapering of 5° to the oval intake port.

[rangergt]

The intake is almost complete, including secondary injector bungs. I just have to jig the setup for the throttle flange and then finish up the metal work to connect it. It looks much nicer now with all that offensive focus stuff cut away lol.

[jfive]

That cast aluminum looks like its fun to weld.

[rangergt]

It welded better than I expected but it's not the nicest stuff to weld as the welds are a little dull. It did weld better than the stock duratec oil pan though.

[AJ_Fritz]

did you run into any foreign contaminants while welding? fireworks!

looks nice man!

[rangergt]

Yes it spit back at me twice lol, contaminated the tungstun but I sharpened the tungstun and it welded fine after that which was a surprise because sometimes when you come across those nasty contaminated areas it`s not fun.

[AJ_Fritz]

that tells you how well it was cast. ive run into aluminum cast that was so dirt it was unweldable, and others that welded so nice it spoiled ya.

[rangergt]

Funny enough, it did weld better than the factory timing cover did.

[AJ_Fritz]

bingo! i couldnt weld a SHO valve cover oil cap housing to my motorcycle fuel tank. it had to have been 30% dirt!

[rangergt]

That`s funny eh, the chinese knock off casting is better quality than ford oem. What`s that say to you?