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ChillyBear, I've been there and done that. Currently I have a Zetec powered ZX2 and my wife drives a Zetec powered Focus wagon. Both are ATX. Check out my gas log to see what a Zetec can give you if you decide to control your right foot. Also check out my mods. I can say that all of my performance mods combined don't add up enough benefit to outwiegh the three aero mods I've done: Grill Block, Air Dam and Rear Fender Skirts. Additionally the aeromods cost me about $50 total. The performance mods, well I'm emberaced to say how much they cost. The only benefit from the performance mods is if the mods help torque at very low rpm, less than 2K, then you can pulse for a shorter time before you glide. I'd say my performance mods help me in this aspect because I can not force my ATX to shift under 2K, so I can accelerate quicker up to the pulse speed. If your driving 80 miles of highway, I also do, then Aeromods will be a BIG bang for your buck. I'd recomend doing them first.
Specfics for the Zetec and Focus. The Focus is already a CAI and in fact it is also a Ram Air. I'd cut off the Ram Air hose and clamp a piece of dryer duct on it so it can pull air off of the header heat shield, this will help. For a slight bump in torque, you can get the exhaust cam from a ZX2 Zetec for almost free from TeamZX2.com. The resonator on the Focus Air box is a non issue, no need to remove it, additionally the stock air box and intake tube are very good, no need to buy an aftermarket one for FE. The Focus sit's realy high, lower it and put some pizza pan wheel covers on for Aero. The Focus can probobly benefit greatly from a front belly pan, behind the bumper is very open. Also, what model do you have? 2dr, 4dr, Wagon? Additionally, I love my block heater! get the Ford one, the aftermarket ones from Kat's fail and don't fit well. The Ford one fits easy and even though it's only rated at 400w and the Kats at 600w, the Ford one works just a quick. I also have an oil pan and trans pan heater, the Kats adhesive backed one. Combined they have benefited me by as much as 3-4mpg this winter.
With the mods done to my ZX2 I can cruise at 50mph and easily average over 50mpg. In my gas log you'll see a trip of 653 miles where I got 50mpg and another 427 miles where I got 54mpg. I also easily surpass 30mpg city. Keep in mind I try not to exceed 55mph on the highway and coast a lot in the city and highway. As already mentioned, driving better will yeild the greatest benefit.
Something to consider: I have about every bolt on mod availble for the Zetec and all my parts are considered the best available for the ZX2 or Focus Zetec. My FE is better than almost all ZX2's I've heard of (only two that I've seen that have beaten 54mpg) and I'm ATX, they are MTX. My ZX2 also holds the Quickest Naturally Aspirated ATX ZX2 time in the 1/4 mile. 15.697 at 88.51mph (I know it's not really that fast, kinda like being the fastest Turtle). I don't see the performance mods hurting my mpg, they are very expensive and are probably a wash in the long term scheme of mpg.
With better aero, Lrr tires and little lean burning, I expect to average over 50 mpg when I am now averaging 42 mpg on my commute.
I've rambled enough, there is more to say, but maybe another time.
Hope this helps!
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