Inlet manifold design


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Ian Mantula
Ian Mantula
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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...

http://www.talkcomposites.com/Uploads/Images/59e2abfc-0ebf-422d-89d0-c5ad.png


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. 

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f1rob
f1rob
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From your picture it dosent look undercut so I would get the "centre" of your item machined in ali or cast in resin then bolt on loose ali flanges either end

Fairly easy part that should come out rather nicw
Ian Mantula
Ian Mantula
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f1rob (05/12/2014)
From your picture it dosent look undercut so I would get the "centre" of your item machined in ali or cast in resin then bolt on loose ali flanges either end

Fairly easy part that should come out rather nicw


The internal bore is a simple loft from a 48mm diameter circle to a rectangle 40mm x 70mm. Thanks for the suggestion f1rob. I could get it all machined but that's beyond my capabilities right now and beyond the rapid prototype company I tried. I don't want to invest a huge amount into these items financially because they are really an interim step towards the ideal inlet system.

GO

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