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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FLD
FLD
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Why not make a loose casting pattern and get it cast in aluminium rather than CNC'd.  Waaaaay cheaper and surprisingly not too challenging to do. 

The other option would be to carve / shape it from a piece of polystyrene foam and ask the foundry to cast from that.  Its a one-shot approach but works well.

Might also be worth a chat with Boost performance as they do a lot of RV8 stuff and might have something suitable.
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