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Joined: Mar 2009
Posts: 48
neil_l Offline OP
Just Getting Started
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Just Getting Started
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I have a Plus 5 (2006) 2.0 Duratec and wondered if anyone has done some tuning on the engine ? I have heard Aero Racing maybe bringing out a Throttle Body and I have contacted http://www.sbdev.co.uk/ who do something similar.

Any advice welcomed.

Last edited by neil_l; 28/11/10 10:49 AM.
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Hi Neil,

I'm also trying to weigh the diffent systems against each other and found the information given on SDB's website the most convincing.
The biggest gains will surely be achieved with modification on the induction side, complemented with a sports exhaust and a more free-flowing cat + ECU reprogramming. These modifications will already take you near the 200 BHP territory. Mild cams may free another 10 - 15 BHP.
My favorite kit is SBD's 214HP taper throttle kit with cams.

However, Jochen (numog) suggested the Cosworth system desinged for FWD applications. This system features only one (bigger) throttle body but long induction pipes for more torque.
He got me thinking with his advice because I now fear that I'll loose to much torque in the lower revs.

On the other hand he'll have to route the air intake around the rear end of the engine because the induction side of the FWD system faces towards the bulkhead. He'll probably modify the hood "TOK-style" to create a "ram-air-system".

I'd also appreciate comments on this matter.

Joined: May 2009
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South Wales Correspondent
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Originally Posted By Marian
Hi Neil,

I'm also trying to weigh the diffent systems against each other and found the information given on SDB's website the most convincing.
The biggest gains will surely be achieved with modification on the induction side, complemented with a sports exhaust and a more free-flowing cat + ECU reprogramming. These modifications will already take you near the 200 BHP territory. Mild cams may free another 10 - 15 BHP.
My favorite kit is SBD's 214HP taper throttle kit with cams.

However, Jochen (numog) suggested the Cosworth system desinged for FWD applications. This system features only one (bigger) throttle body but long induction pipes for more torque.
He got me thinking with his advice because I now fear that I'll loose to much torque in the lower revs.

On the other hand he'll have to route the air intake around the rear end of the engine because the induction side of the FWD system faces towards the bulkhead. He'll probably modify the hood "TOK-style" to create a "ram-air-system".

I'd also appreciate comments on this matter.


Another throttle body set- up which is very well worth looking at is the one produced by Jenvey Dynamics ( especially the taper version which packages much better.)
http://www.jenvey.co.uk/
For general Duratec info, the Raceline site is also a useful source of comment:
http://www.raceline.co.uk/products/index.asp?categoryID=1

So far as the routing around the rear of the engine is concerned, I've been looking carefully at this myself and my conclusion also is that since the best high pressure area is up against the bulkhead, then the inlet duct needs : (i) to be very close to that area and (2) the length of the duct itself needs to be kept as short as possible, so the 'Supersports cowl' idea may well be the way to go.

I priced the cost of obtaining a half- bonnet with a cowl from a well known Morgan sheet metal firm and the rough cost was about 430 GBP ( If I was happy to use the exisiting half bonnet with the cowl riveted on, then the price was much less
G


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I have A thread on here somewhere which shows an installation of a ram air induction system which solves the problem of Cylinders 1 & 2 being ahead of the inner wheel arch.

Good to see someone getting to grips with the 2.0 Duratec motor!!

The nice thing with the Jenvy system is that is is the same dimentions as a DCOE therefore you have options on the housing side.

Alternatively there is a Cosworth (I think) throttle body for the Duratec which is roller barrel. It is overall shorter housing and does not suffer the same turbulance as a throttle butterfly system at WOT.


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South Wales Correspondent
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Originally Posted By cerealsurfer
Alternatively there is a Cosworth (I think) throttle body for the Duratec which is roller barrel. It is overall shorter housing and does not suffer the same turbulance as a throttle butterfly system at WOT.

Do I recall Titan doing something similar?

Cheers
G


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Yes sorry it was Titan


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Originally Posted By cerealsurfer
Yes sorry it was Titan


No probs- the only reason the name stuck in my mind was that it kept cropping up when I was investigating multiple throttle bodies on the Zetec

Funnily enough, I thought there might have been something of use on the 'Puma Race Engines ' site but unless I'm looking in the wrong placr, I couldn't find anything
Cheers,
G


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Bear in mind that the quoted bhp for the car in standard form needs verifying on a set up because one needs to know where one is starting from: my guess is it will not be 150bhp. Meabh.

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Originally Posted By cerealsurfer
I have A thread on here somewhere which shows an installation of a ram air induction system which solves the problem of Cylinders 1 & 2 being ahead of the inner wheel arch.

Alternatively there is a Cosworth (I think) throttle body for the Duratec which is roller barrel. It is overall shorter housing and does not suffer the same turbulance as a throttle butterfly system at WOT.


Ah, well...
Could someone please take the time to explain that in some more simple words? somestick

The problem of the air supply aside, I'm still trying to work myself through the different systems on the market. Which one is best suited for everyday use of the Morgan and - say - some Track days?
"Streetability" must be ensured.

I'd like to learn more about the following inductions kits:

1) Raceline / SDB / Jenvey "DCOE Weber style":
http://www.raceline.co.uk/products/part_section.asp?SectionID=13&CategoryID=1
2)Cosworth barrel throttle kit
http://zippyracing.co.uk/shop/catalog/cosworth-duratec-2023l-barrel-throttle-45mm-p-687.html
3) Cosworth D-Power Plenum
http://www.part-box.com/cosworth-d-power...us-p-11968.html
4) SBD's tapered throttle bodys
http://www.sbdev.co.uk/Duratec/Duratec%20Basic%20Taper%20throttle%20kit.htm

Confusing I must say... Which one will work best und the given circumstances and restricted space under the hood? I'd need to point out that I want an air filter and that I have to avoid any modification that is visible from the outside. None of the above tuning kits will comply with Swiss legislation and I don't want to draw even more attention... innocent

Which path shall I follow?

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Induction tuning comes with several considerations:

Length of the induction pipe - this is measured from the back of the inlet valve to the point at which the overall itake assembly reaches open air.

Cam timing - indicates the pulse duration (used to tune length)
Exhaust Port Size - The size of the hole in the Cylinder Head and it's matching to the Inlet manifold, throttle butterfly etc. Ie. ensure enough air can "get in" to the cylinder.

Expected Engine Operating Speed - This is important when looking at high power manifolds, as it dictates intake air speed... it indicates the location of the injector in the inlet tract.

Cold Air Source - Where do you get Oxygen from

High Pressure Zone - where is the air the mose dence.

Raceline/Jenvey (I will consider SBD's onwn seperately) - These offer derect to head mounding and copy the format of DCOE's. They have post Butterfly injector position which will give good mix duration for all but very (very) high engine speeds. They are also single injector housings (which back up again the usual rpm range usage). The rules for butterfly sizings again match up to DCOE recommendations so you can google DCOE recommendations to get a good steer for sizings.

SBD - SBD use individual Throttle bodies which have been selected for air flow matching to the Duratec. They have then tuned the length and shape of the manifold seperately to get best torque whilst maintaining max power output. I'm sure I have seen a multi injector rail version of this on a Westfield which allows for Bank one of the injectors to run in the stock position giving regular running and then a second bank placed towards the intake end of the runners (possisbly even pre butterfly) to cut in at High RPM and probably WOT thereby giving enough time for the fuel air to mix correctly.

Barrel Throttles - Do the same as the SBD TB's but instead of using a Butterfly use a rolling barrel. You will still need to get a suitable inlet manifold to mate these to the Head and air-horns etc. So similar to SBD but minus manifolds.

Cosworth D-Power Plenum - This is slightly different from the above in that it includes an Air Box (which can be put onto all of the above) with a single much larger throttle butterfly and it's likely that it is pulse tuned. By dictating the length from the valve and knowing the likely cams used etc. Firstly it will reflect the individual Intake pulses back into the individual intake tract,.... hopefully making the pulse reach the back of the valve just as it re-opens.. which means that you get a slight "charge" effect therefore a "bit" extra power. You can also scavenge from other cylinders, ensure a generally dense air situation inside the plenum etc. etc. The single throttle is ok but will not let you tune individual intakes to balance cylinders. You will also get more torque as you have effectively enlarged the intake tract all the way to the hose you will need to fit on the front of the single inlet pipe.

Weber also do an "Alpha" injection kit http://www.webcon.co.uk/alpha/AlphaGoldKits.html

If you want an easy application then the Jenvey kit or the Weber Alpha kit are more straight forward.

You will need to think about a closed intake as you have a bonnet and an inner wheelarch which will be Very close (think Cylinder 2 being <10mm from the end of the Jenvey intake (without air horne or air-box).

Pipercross do a slimline airbox which fits under the bonnet with some minor work.http://www.pipercross.net/competition/products_600_airbox.asp
Alternatively there are Carbon versions from Riviere which are more expensive (a lot) and will need more creativity that I've mustered to get to fit!

http://www.reverie.ltd.uk/

I hope this helps somewhat... alternatively you need to read this book:

4 Stroke Performance Engine Tnuing - A Graham Bell

http://www.amazon.co.uk/gp/product/18442...7C0TWAMDJJE3DMK

Good Luck


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