Well you have seen the ad where the Duracell bunny starts the entire East Coast generating grid. I thought they would start the car and be lighter. Just kidding.
Here is some more little progress. I found a picture of an F2 customized Duratec head showing the EGR exit at the far right. F2 head Pic below. It looks like there is no water jacket exposed there at least on this custom head. The cavity between the two center inlet ports appears to be a dry cavity on this head as well. I am hoping for the same on the stock head. It will be easy to hook up my copper manifold to the egr tube coming out of the head with some suitable fittings. I will try and order a spare to get started.
The second picture is another view of the airbox showing the short trumpets that will come out of the throttle bodies. There is a small spacing difference between the throttle bodies and the intake manifold runners. This will be made up by flexible connectors. The plastic runner inlet will be ported and tapered to make the air travel as cleanly as possible. I found a 4 inch flanged plastic inlet at Spectre along with a 4 inch to 3 inch silicone hose adaptor. This will be attached to my cold air intake. These will both be black and lend some factory look to the installation. The cold air intake system will be mostly Cosworth followed by a Focus Sport section of larger diameter feeding the 4 inch inlet. I should be able to remove a lot of the bends. My cold air system already has an air box and snorkel at the inlet side so the filter is completely enclosed and it does not have problems with water entry in high water. Details are in a topic on the right column of my Journal.
The Suzuki airbox material seems to be ABS. I am going to try some ABS glue or maybe gas tank repair material to seal some of the openings I have created.
This view of the airbox shows the short trumpets that will help tune a little wider RPM range than a sqared off tube. This filter has been removed and the inside reshaped to maximize airflow to the trumpets.
