Im presently trying to make a manifold to fit throttle bodys to my Zetec and am finding it hard to match the round pipes to the port shape. I could squash them and then try and match the shape after welding but have been trying to keep the pipes as round as possible.
I have made a plate and put one inlet pipe through at an angle, but this means that there is a large step at the bottom of the inlet port, I would like to grind the port top match to the manifold as it then means I dont have the miss matched section at the top where the original injector clearance was.
I have attached a picture to show what I mean the area is the lump enclosed by the blue marker pen line, does this look ok to do or a bad idea? im assuming that there is no water ways in the area just below the port at the manifold face.
Paul.

I wouldn't. You will end up with fuel puddling there as the cross section will be much larger so the air will slow down. You may also find a waterway!!

I have used ally tube squashed to an oval at the head and then ground to match the ports after welding to the flange.

I have ignored the injector cutout as a step in the right direction will not hurt. It will actually be a benefit with wilder cams as it will hurt the reverse flow with big valve overlaps.

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Originally posted by TangoMan
I wouldn't. You will end up with fuel puddling there as the cross section will be much larger so the air will slow down. You may also find a waterway!!

I have used ally tube squashed to an oval at the head and then ground to match the ports after welding to the flange.

I have ignored the injector cutout as a step in the right direction will not hurt. It will actually be a benefit with wilder cams as it will hurt the reverse flow with big valve overlaps.

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