By Ian Mantula - 12/5/2014 12:14:14 PM
My interest in composites for my Marcos project started as a way to create a part that was too expensive to CNC machine out of aluminium. The V8 engine originally lived in a 2001 Range Rover - plenty of room under the bonnet. The Marcos is a much smaller car with a very low bonnet line. This has required a rethink on the inlet manifold design. While I can keep the cast runners, I have had to discard the single large throttle body. I will use two 48mm Jenvey throttle bodies. To mount these new throttle bodies I will need two asymmetric mini-manifold parts. Here is a rendered view of the CAD model...
 Now, having failed to get this economically made by other methods I hope to try it in carbon fibre, but is this a realistic idea? I'm sure that this could be made with a two part mould, but how would I build the flanges? How many layers would I need? Would I need to alter the design to ensure long-term strength? Any comments and suggestions would be very welcome. Ian
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By scottracing - 12/14/2014 12:39:55 PM
if its a one off and you can afford it there are suitable 3d printed materials on the market for this application, im currently working with a company over here in germany that uses a glass fibre reinforced nylon for prototype car parts for under hood applications, most of the OEMs use the parts for dyno and road testing as they are suitable for llonglife use, have a look at www.igwmbh.d
There may be something suitable in the uk too,if you ask companies like laser lines or amalglam they might be able to help.
But as f1rob says the overall pattern to make shouldnt be too difficult with a split mould and then two flanges at the end you can either bond on or create carbon flanges, i would add dome metallic bushes in the bolt holes just to be extra fancy and possibly cast a silicon mandrel of the internal shape to give you a really nice smooth surface.
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