Scott D's next MK1 Escort Project

[Danny M]

Which program is it as that is going to turn into a pig!

[ozstang65]

Pipemax

This is what's on there now, quite similar overall length, but bigger. 2.25" the rest of the way to a single oval muffler (straight through) and a side pipe

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Primaries (all different lengths):

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Secondaries:

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Collector (if you could call it that..):

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[ozstang65]

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[Danny M]

Scott just because it's a computer program that's available on the net doesn't mean it's a good one
Go and have a look at the Tuning Four Stroke Engines book by A. Graham Bell
Peter and I have used that formula and many things and it always comes up very very close as I'm telling you now those figures you've got are so far out of the ball park for a pushrod it's not funny

[ozstang65]

How about what i'm running now then?

[Danny M]

What you have now will make better power than those big ones
Those number you have, have the same diameter secondaries as mine on the YB except they're a lot longer which will make it even worse
Even Craig's pipes would be a little big for yours in reality

[ozstang65]

The ones I have on the car now are bigger diameter than the ones i'm making and are roughly similar lengths. The pipemax output i listed are pipe ODs, not ID.

[Danny M]

Which ones are going to use, the ones from the text or the ones from the CAD drawing as I wouldn't use either

[ozstang65]

The CAD model is done using the middle set of numbers from the text. Primaries are 1.25" tube, secondaries are 1.5" with a step to 1.625" at half length. Primary and secondary lengths are 360mm each section. I can't see how they could be worse than what i have already.

[Paul T]

Primaries 1.5" O.D x 15-16" + collector
Secondaries 1.750" x 10" - length critical + collector.
Tail pipe min. 2" length dependant.

Not found using web formula.
Not found reading a book.

What has proven to give best spead of torque and best HP on FF1600 race winning engines built and tune by me and used on road engines that are somewhere near that spec.

Also there will be a Mk2 Escort on the way to QLD shortly with an Xflow that has in no way failed to make pinto numbers.

[ozstang65]

What sized ports are in the head Paul? 1.5" OD pipes are 34.8mm ID so there would be quite a step between the head and the primary tube in my case.

[Paul T]

Since your going to the trouble to make the pipes come off the manifold flange at 1.375" for 1.5" then step up to 1.5".

There will never be a substitute for actually testing things.

[ozstang65]

Thanks Paul. My testing is limited to an Oxygen sensor in the exhaust with a readout on the dash and my track times. I'm not seriously enough into it to be spending big $ on continual dyno testing so any development is done a step at a time. If i go faster at the next event it was a good change, if i go slower then i'll revise the decision! Sofar every change i have done to the car has led to a bettering of lap times and i enjoy the fact that i personally have developed the car to where it currently is with absolutely minimal outsourcing (as is pretty comprehesively documented in this thread). I gather as much information from as many different sources as i can then make a decision on which way to go. It's a great learning process.

[ozstang65]

Slow progress at the moment, hoping to step things up the rest of this week. I've welded stubs into the manifold flange so that I can reach through and make sure the ports match up before welding the rest of the primaries on.

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Also, continuing to make the jig to start assembling all the bends and collectors.

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Made the final collector thisarvo, beginning to get the hang of the TIG

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[ozstang65]

More development on the jig today, figuring out a method to hold the pipes in place. I welded bolts to the jig at known points and then used some tube with nuts welded to the end to make adjustable/removable posts. At the top end I cut and shaped some 1mm sheet and held the lot together with hose clamps. Seems to work quite well and it makes adjusting the pieces around quite easy. A couple more bends to cut out and then the jigsaw can be put together.

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[ozstang65]

The jigsaw is finally coming together.

I sorted out the inside runners first.

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A minor error when making the collectors, fixed with a small infill piece.

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Trial fitment showed all was good.

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So onto the outside runners. Only some minor alterations required.

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[ozstang65]

All tacked together now. Weld out tomorrow and then the rest of the exhaust.

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Old vs New

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[PaulMK1]

Impressive

[stuart]

nice work ! ill be interested how well they work if they are good i might be putting in a order : )

[jsa]

looks the goods