zetec throttle body adapter

grabcad

While refining my Zetec build, I encountered a challenge: a "black top" engine intake manifold differs from the sealing method used by its predecessor, the "silver top," aluminum Z manifold and TB. The vintage inlet features a flat mating surface that utilizes a paper gasket (interestingly, I discovered a metal equivalent at home), whereas the newer version boasts a 1.2mm protrusion; correspondingly, its throttle body incorporates a concave recess to accommodate a rubber seal. Moreover, the plastic parts' ICV channel is notably shorter than before, necessitating an improvised solution to avoid introducing unwanted air. To mitigate this issue, I experimented with different adaptations. Though it's just one iteration and far from perfect, I successfully implemented the rubber seal without encountering significant difficulties. However, a possible alternative to resolve these discrepancies might involve employing a silver top-style gasket.