Sorry ive not been on for a while, ive been working away from home, and not really had time to get on here!
@ Clarkie
you mentioned the above when you listed everything but what are the minor details?
im guessing you used the escort/fiesta rs turbo exhaust manifold and replaced the flange with the standard puma one to make it fit? and i know you made the downpipe yourself so im guessing again you chopped off the flange and added your own custom bit on from there?
and when you say you used the modified excort turbo exhaust does this mean i will loose my miltec system or does this mean i just need to modify it to fit? id rather not chop up the miltec but i will have a custom flange made up to make them fit.
No, i used the standard Puma exhaust manifold, and got a T25 flange welded to the bottom of it, as the spacings and port sizes of the RS turbo are different, and cant really be changed on cast, so would cause alot of power loss on a turbo set up due to turbulence!
For the downpipe, i brought 2.5" bends, and a saab 9000 downpipe (as thats the turbo im using), and cut the flange off the downpipe, then cut and welded the bends to suit, and then used the rest of the downpipe to fit it to where the cat back starts.
For the exhaust, most people dont realise that the shape of the fiesta RS exhaust is exactly the same as the puma/MK4/5 fiesta, so you just need to extend by about 50mm, and move hangers about, and youve got a 2.5" bore exhaust, for pennies!
You can keep the miltek catback, but the 4-2-1 will have to go!
the idea in my head is an rs turbo exhaust manifold with a standard 1/7 exhaust flange and gasket to fit it. the next bit needs to be custom right? so use the standard flange from the manifold then add your own custom pipe work then put the stnadard puma flange on the other end to mate it up to the miltec flange or if the standard one dont work ill mate it to the miltec flange. either way this should work right?
As far as im aware, the rs turbo port spacings and shapes are slightly different to the puma, but just check it 1st, but id be more inclined to use the puma exhaust manifold, and then chop the flange off the bottom, and get a plate and turbo flange welded to it. The 2 turbo pumas on here putting out decent power are both using this idea! The bit from the turbo to the cat back needs to be custom, but its quite awkeward because the bend radius is VERY tight! Then you can put whatever flange you want on there to make it fit your existing cat back.
@ yippeekiay
Yeah, I'd like to see a picture if possible of the manifold, turbo and turbo exhaust exit into the exhaust system. I understand how they're routed to the turbo using the modfied flange to the manifold but my head can't get round how the exhaust gases are taken away from the turbo, is that the reason for the custom downpipe?...I think I may have just answered my question but not 100%...lol.
Yes mate, you just answered your own question lol!! You just need a way of getting the gasses from the turbo, out the back of the exhaust,in the most efficient way. Ive tried to get picks of the exhaust, but its really difficult, as theres no space, the only picks ive got ill post up, i have some of the downpipe, and some from under the car. Ill be taking the engine out soon, so ill get some picks of it out of the car, it will be much clearer then.
I do have an eaton supercharger off a mini, and your right, its Massive, i was going to put it in place of my A/C compressor, but even with that gone, there just wasnt enough space! No doubt it is possible, but just wasnt worth the hassle for me.