It's now Nov '05, Tank2 Is finished except for the wiring up the ECU, the rebuild has proven easier than expected, though it also took far longer owing to my work commitments. I'm really looking forward to next summer '06 when I can use it in anger. The best bits of the build for me were making the Fuel injection system, including the inlet manifold, and the exhaust. I used Lotus Esprit TB's [£75] which unfortunately use a non standard barrel spacing, this necessitated making up a custom inlet manifold to enable their use on a Zetec.

Many thanks to the guy's at PPC mag for their inspiration on this subject. I'd never have thought it could be so easy to make up an inlet manifold, mine is made from Stainless steel. I'm using a 'K'series fuel rail and injectors, these have the 90mm port spacing like the Zetec [and Vauxhall XE!!] though the injector size may need changing during the rolling road engine ECU setup session. "nope injectors were correct! So say's Dave Walker March '06"

Another part that required modifying was the fuel tank, I decided to use a Ford Sierra 'in tank fuel pump' and also the swirl pot [see photo] , I'd used similar items on my Dutton and Robin Hood 7 so I know that the system works reliably with a Zetec. I retained the original S4 sender for the fuel gauge, though the Sierra sender would probably work OK with the Smiths gauge fitted to an S4.

The exhaust system was also enjoyable to make, I used Stainless steel [60mm in diameter]. The exhaust fitting is identical to the original S4 item, and, excepting the pipe diameter would be indistinguishable from the original. Manifold is a high quality stainless Westfield Item @ £250. That's cheap compared to 'Racelines' @ £550 hmmm how do they justify that cost???????

To fit the manifold I had to re-cut the exit hole in the n/s panel 2" further forward. This isn't noticeable at all on the finished car.