Hi Bob, my answers below.
Dave, I’ve been reading your posts on the mods you have made to Montegue with great interest. Can you clarify a couple of points please:
Is 180 bhp available without changing the cams on a standard Duratec.
Absolutely 
Did you use the standard cat and if not, are there any emissions problems
No, I used a 200 cell cat and my MoT tester flexible 
Does the guide price you mention include fitting?
Yes, because Fusion Fabrications will build the exhaust and inlet manifolds on the car.Many thanks
Bob.
In addition to the above, if you're setting your goal at 180hp and you want a quiet car that passes the emissions test, save the money on the 200 cell cat, sports silencer and tailpipe that I went with. Ask Matt at FF to integrate your factory cat and keep the rest of the system as is, the big power gains come from the long tube Supersports exhaust manifold which you definitely want.
The inlet manifold works brilliantly, but with the exhaust manifold your Duratec is now shifting a lot more air so without a remap the engine will run lean and feel as flat as a witch's mammary gland! Putting a richer fuel table into the Ford/Visteon ECU sounds easy enough and on the face of it, it should be. However, I found it 'nigh on impossible' to find someone prepared to work with the old Mondeo ECU, saying that 'Rog' who regularly posts on these pages has a remote mapper who can hack the ECU so he should be able to help?
I became inpatient to find a solution and because I already have quite a bit of experience with aftermarket ECUs and I was taking Monty to the next level I fitted a plug-n-play EMU Black from ECU Masters which is an exceptional engine management system that will allow further development of Monty such as the installation of a Rotrex supercharger.
However, don't rule out the old Ford/Visteon Ford ECU, it's a quality and very capable system (if rather outdated) that can easily cope with 180hp on the stock injectors, all it needs is a richer fuel table and your Duratec Plus 4 with the FF manifolds installed will easily make a healthy 180hp. The standard setup with the plastic inlet, restrictive swirl flaps and the dreadful exhaust manifold makes 143hp, now add the best part of 40hp and because the car only weighs 900kg or so you'll really notice a big improvement in performance.
The Duratec is one of those rare naturally aspirated engines that responds brilliantly to a few simple breathing mods, the reason for this is Ford got it right first time with this engine, despite the engine being fitted to really boring cars like the Focus and Mondeo if you actually take a look at the cylinder head it's an absolute work of art, the ports are huge and well designed and the combustion chambers are pure race car.
Testament to the brilliance of the Duratec is the fact that the factory cast ports are thought to be so good straight out of the foundry that it's common knowledge there's little or nothing to be gained from CNC or hand porting the cylinder head, and that's very very rare indeed!
