Project Overview

A local car enthusiast in Mandurah, WA approached Rescan 3D to develop a custom intake manifold for a classic car, combining features and geometry from three existing manifold designs with a number of new requirements.

The donor manifolds were 3D scanned to capture important geometry including flange angles, port locations, bolt patterns, coolant passages and distributor mounting features. Rather than simply reproducing an existing component, these features were used as the starting point for an entirely new design.

Services: 3D Scanning · Reverse Engineering · Mechanical Design · Design for Manufacture · 3D Printing
Application: Classic Automotive
Approximate Size: 500 × 260 × 110 mm manifold, plus supercharger adaptor and intercooler assembly
Deliverables: STEP CAD models · PDF manufacturing drawings · 3D printed prototypes

The Challenge

The original manifolds were cast components, allowing shapes and internal features that can be difficult or impossible to reproduce when machining a replacement from solid aluminium.

The new manifold therefore needed to combine the required geometry from the donor components while being practical to machine from aluminium plate. The design also incorporated many new features, such as multiple additional sensor ports, relocated coolant ports and mounting features for the new intercooler system.

3D Scanning & Design

The three donor manifolds were 3D scanned and used as references within CAD. This allowed important dimensions and features from each component to be incorporated into the new design without simply copying any one manifold.

The new manifold was designed around the required engine interfaces, internal passages and available space. Particular attention was given to ensuring features could actually be reached by standard machining tools and avoiding geometry that would make the part unnecessarily difficult or expensive to manufacture.

Although designed to be possible to manufacture using a 3-axis CNC machining centre, the completed part would be well suited to 5-axis machining.

Supercharger & Intercooler Integration

As the project developed, the scope expanded to include a custom supercharger adaptor and integrated water-to-air intercooler.

A donor supercharger adaptor was scanned to capture the required mounting pattern, while the new adaptor was designed to provide the space and airflow path required for the intercooler between the supercharger and intake manifold.

The coolant fittings were also modelled in detail to ensure the complete system would fit within the available space. Rescan 3D worked with the fitting manufacturer to adapt an existing bulkhead fitting for the application, allowing custom fittings to be produced specifically for the assembly.

Prototype & Fitment Testing

Rescan 3D supplied prototype 3D prints of several iterations of the manifold and associated components for physical test fitting in the vehicle.

This allows fitment, clearances, and mounting points to be checked using relatively inexpensive prototypes before committing to CNC machining the final aluminium components. Changes identified during test fitting can then be incorporated into the CAD models before manufacture.

The Outcome

The project has developed from three existing manifold designs into a completely new intake system comprising a billet intake manifold, supercharger adaptor and integrated water-to-air intercooler.

The current design combines the required features of the original components with new functionality while being designed specifically around CNC machining and the available space in the vehicle.

Once final vehicle fitment testing is complete, STEP models and detailed manufacturing drawings will be finalised for manufacture.