Finally someone that really makes everything on it's own, really cool to see what it's possible to do when n you wan't to use simple tools

The rotary community needs you this is amazing. With love from Mass, CT neighbor.

Seriously Impressive. I've spent 20 years building out a full CNC machine shop business. With the end goal of building a car from scratch. It's looking like I could have just waited and 3d printed everything thing instead of 5 axis CNC everything. 3D print with some light finish machining is the future it seems.

This opens up whole new ways of passing visual emissions requirements while gaining performance.

those welds made she shed a tear. beautiful

On flattening, I've also had luck using a mid-high grit sand paper glued to granite or glass as a flattening surface. Awesome work on this project! I also really dig how you are 3d printing jigs for machine work. I should have done this when making my fuel rails!

The black wrinkle finish is exactly what I was thinking.

This is gonna end up 100k+. And I'm here for it! Love the project, man.

This is incredible. Many rotary people suggest to add a heat shield between the intake manifold and the exhaust/turbocharger, it might have been nice to add a provision for that onto the intake manifold. Thanks for addressing the flange flatness, I wouldn't trust most of the belt sanders that I've used but it's it's hard to argue with a feeler gauge.

I work in the additive industry in SLM technology and it was very refreshing hearing and seeing your knowledge through out the video as you work with the printed parts you received. Metal AM is even more exciting for me when I see it in automotive application. Most definitely subscribing.

Looks good. I think I would add some support between the intercooler and the engine just to take some of the load off the runners

Completely awesome! I recently designed a throttle body adapter for a 13B intake manifold, which is a much smaller task. It was still very interesting to get quotes on having it CNC machined or 3D printed. I was surprised how expensive 3D printing metal was, but as the price comes down it will become more and more viable! I think for a seriously complex item like this where the cost of CNC would be so high, it's already reaching that crossover point. Not to mention when the geometry would be literally impossible for CNC as a single part. Really appreciate these videos!

Your channel has given me hope to keep so many older things on the road.

First time viewer. KZfaq recommended this video to me and I'm glad I clicked. Very neat presentation style, you're straight to the point but also good at showing/explaining everything that's going on and why without making it too drawn out. Will catch up on the rest of the vids and tune in for more 😃

This is absolutely amazing work. Loving this series.

Happy to get another good rotary content fix so Rob can focus on pikes peak prep!

For paint, Cerakote Glacier Black would be pretty nice. It's hydrophobic and easy to clean. Then just sandpaper the lettering. Another option would be to vapor blast the whole thing and clearcoat it with Cerakote MC-5100. That stuff is extremely hydrophobic. -- What an amazing time to be into cars. We can literally just print things. I suppose I can have that BMW M88 I've always wanted.

This build is really turning out super sick. Never realized how accessible 3d printed metal parts were, definitely want to find a way to implement that in a future project myself. Thanks for posting and showing the process!

I was wondering about flatness but trusted the process. I definitely didn't expect the bench to be that curved! You need a drainhole in that thing :P

As someone who has been designing and developing his own 13B inlet manifold for the last year or so, this couldn't have come at a better time! While I was alreadly looking into getting some more intricate pieces printed and then weld everything to CNC machined flanges, the idea of printing the entire thing didn't seem in the realm of possibilities until now. Thanks for showing this, and keep up the good work!

That's not bad for a one off completely custom unit. Sheet metal custom IM are similarly priced and you don't have nearly as many weld points. Thank you for sharing your journey with us.

Wow! How does this channel only have 6k subscribers? This is such high quality content. Discovered it by accident but subscribed immediately. Love to see it.

i subscribed just to hear this motor run

Absolutely fantastic start to finish.

Nice videos man. But you should have also welded the middle bar of the coolant intake on your intercooler. Wouldve been quite easy, just cut the intake cap on one side of the middle bar in half. Wasted performance, and, water could get pressed through the gap between the core and the middle bar and create cavitating. I know, highly unlikely at such low flow rates, but just a tip.

Damn that twin power turbo on the manifold is a really cool detail, the project is looking great 💪🏼

one of the COOLEST segments ive seen in a while! holy moly you are a talented fabricator, great engineering and you truly seem to have some intelligence. PLEASE MAKE MORE CONTENT! FULL SUPPORT

What an OEM will probably take years to achieve and build. Awesome stuff!

crazy level ingenuity and detail for "home" builder. subscribed!

Quite impressed with the finsh and price for such a large item printed in metal

First of all mad respect for the time you spend thinking, 3D modeling etc. This is the real shit, this is a real build not bought car when finished. You earned yourself a new subscriber. At the and of the video you let us give you ideas About any Color for the intake manifold. You said powder coating but Maybe cerakoting it would maybe be the beter option. Here me out why, cerakote is excellent in keeping heat in the material itself prevending ir heat for example: turbo manifold, exhaust etc. But cerakote is not only excellent in keeping heat in the material itself but also heat protection, for example the ir heat created by the exhaust manifold, since its good in keeping heat inside the material itself also means it needs a lot of ir heat to pentrate the cerakote layer and start heating up the aluminium itself and thus automatecly heating up the air inside the manifold itself and hotter air means less oxygen less oxygen less fuel less fuel less bang less bang less hp. not saying That powder coating is a bad idea, but cerakote c series is aircuring instead of oven curing like poweder. And c series had the same strength as oven curing cerakote. And since all parts are already sandblasted what cerakote needs to bond maybe a thing to consider. Why you think, because the ir heat protection since the exhaust manifold and intake manifold are close to each other. Maybe considering cerakoting the exhaust manifold as of the part about keeping the heat inside the material, Sorry for my maybe sometimes wrong writen words Greetings from the Netherlands🚗💨

I used to have a friend who worked in a marine diesel engine shop. They had a massive belt sander (a "belt resurfacer") that they used to surface things, including marine diesel heads (which are usually one cylinder per head). I had them flatten many a header flange for me. That has a machined flat surface that the belt runs on and a high quality belt, but I imagine any decent belt sander is good for an exhaust manifold.

You’re the king of cool in my eyes.

Wow just wow! What you are doing still amaze me! What great work!

Well I'm certainly envious! Great work, the parts looks wonderful and it's quite the interesting project. A rotary in an i8? Interesting. I designed a manifold for my 12AT a year or so ago and have just been waiting until I can afford to get it printed in a similar fashion. Definitely look forward to a decade or two down the line when this tech gets a bit cheaper. It's hilarious how similar the design is too, granted I guess there isn't too much to deviate on the rotary platform. Sorta fun to almost see "my" concept come to fruition through a different lens. I have the same issue of no center-iron injectors because it's a 12A so when I said it's a similar design I really meant it, it's almost uncanny with a few differences up top with the plenum. Currently I run the factory Nikki carb intake with a printed CF-PA "injector adapter" that holds the throttle and injectors and everything. The injectors are way too far away from the engine for decent drivability but it does work and makes good power. You sort of have to make do on a uni-student budget so it is what it is. DBW also helps keep things a little more tidy since it saves the need for an IACV (which it used to have) but a proper custom manifold is definitely the goal. Anywho, pardon nerding out a little, it's just so cool to see basically the same thing I've been wanting to do for approaching two years now. Absolutely love it, great work! Edit; just got to the fuel rail bit and I did the exact same thing! 3D printing jigs has been a massive aid in working on custom automotive stuff. I made drill jigs for moving the oil gallery connections for the oil pump outlet and front bearing feed (both to the front iron) as well! Minor stuff I know but I'm just nerding out, apologies. Cheers!

I am geeking out watching this build. Love all the walkthroughs and explanation.

This is really cool to see. I love seeing 3d printing used for automotive parts, its rare that i get to do it on my own car since i cant afford metal printing but one of these days i hope to do lost pla casting to make a self made engine. The fusion export issue has to do with the level of detail settings when you export, fusion is honestly terrible at import and export stuff. Itll add more mesh the more features youve got in the area, so if its just a large tube it ends up low rez unless you turn the resolution up to a frankly ridiculous level. Until recently i was using fusion, but they booted me from the startup edition i was learning on, so ive switched to seimens solid edge (fully featured and free to makers and hobbyists) and honest to god its night and day better in every single way. One of these days ive gotta write a thank you to autodesk for forcing me to learn something else because noone would use fusion if they knew how much better everything else is. 😂

That's way cheaper than I thought it would be. Prices have really come down. Can't wait until I can do it at home.

Super impressive stuff, irony is I took the 13b out lol Really interested to see the final i8, such a great looking car.

The fitment is amazing, subscribed !

Very nice work! I can't wait for the final result.

I'm so glad I found your channel!

You’re a legend!

I KNEW this is coming

I like the way you follow precision

Great results . Should work a treat.

That came out really nice. Great job!

Love the content. Love how you show your basic fusion360 info, and then the final part... not hiding issues or gotchas either. I do wonder why the velocity stacks have a gap under them? if they were flush with that plenum "floor" there would be nowhere to trap debris and be just as smooth. Is there a function for that gap that I am unaware of?

This is so cool. Beautiful work!

Really nicely done and fascinating. Thanks

Your content is so satisfying to watch! Awesome

Great work and explanations

This is awesome

this is pretty amazing

You can make 3D printed aluminium stuff now?! That’s insane! Imagine the possibilities!

Sweet stuff, glad i found your channel

Pretty sick stuff. Nice one

Tis is awesome.

Love this channel

Just found this series and I am all about it!!!! Been thinking about engine swapping an I8 and knew about the engine constraints. Just binged all your videos then also Robs 13b 700hp video. Any reason why your not going Nexus? I assume its the BMW support for the CanBus on Max. What are your HP goals, why EFR? Not that smallest turbo to put within a restricted space. Awesome to see another New Englander jumping into a project like this.

Cool build. New sub. Key word is "reasonable". If your method achieves satisfactory outcomes, then send it!

Another great video. Keep them comi g

Subbed. Wish you all the best with your project(-s)!

I’ve found that when exporting meshes from some cad software; the angle from which you’re viewing the part at the time you export it can effect the resulting mesh

I am very much interested in the thermal pressure and abuse this is going to see. Starting and ending measurments for the race season, i want to know how much it tweaks under abuse. Those welds on the heat exchanger have a tough job ahead of them. I would keep it at 18 lbs of boost briefly. 24 lbs put on your balistic saftey glasses, P= (2*T*S/D) for your weld should help. Ironically you have a license plate behind you that says bad idea.

Loving your content!

Очень интересный опыт!

Great work. Thanks for sharing. Did you think about dimple dies on intake runners? (Golf ball sufrace)

Is part shrinkage ever a problem or is it not a concern? Your channel has inspired me to try making more of my own parts this way. Thanks

Wrinkle black might be too much, just satin black with polished lettering and ribs would be amazing

👍👍👍👍👍

Blue and White to keep the i8 scheme?

Wow it's beautiful, you modeled all of that in fusion 360?!

Also, you may want to do full FDM 3D prints before you send out final files Shrink them to make it so it doesn't take 3 weeks to print :P But when I do 3D prints, I ALWAYS miss stuff, and printing test copies helps me catch things

👏👏👏

The belt sander needs to be flat to ensure an accurate result. The straight edge needs to go on the sander first.

Please consider doing a thermal dispersant on the intake plenum with a ceramic barrier on the exhaust and hot side of turbo..The company we used for the racing industry is techline coatings. You can even coat the hot side of the turbo...

Is the printed aluminum dense enough to polish or would it be too porous to achieve a nice finish.

Very cool technology! Question: Why are the inside runners smaller diameter than the outside two?

Hi, great series you have here. Just wondering where you purchased the intercooler core?

Given that flatness and smoothness are not at all the same thing, are you pretty confident that the belt sander did a decent enough job creating a smooth surface on your mating surfaces that you wont have problems getting it to seal?

I notice no support bracket in your design, are the 3D printed SLS runners strong enough to support the entire assembly?

Interested in doing this same type of manifold for my twin charged hybrid crz….. anyone you would recommend to sub the design out to?

How is the strength of printed aluminium compared to cast or machined billet? In other words, how much do you compensate for what I presume is a lower strength part?

Can you ask them to forgo the sandblasting entirely? This seems like an unnecessary risk for an intake manifold without much benefits

Nice job. Adding filler with bare hands is not good way. You are also adding your sweat to your welds.

Have you tried vapor honing one of those aluminum 3D parts?

I never saw anyone addressing 45 degree seal for the Bosch pressure+temp sensor, I have couple of those installed with copper washer under the sensor and it seals this way. Can you share any sources that describe correct installation procedure?

Wouldn't equal length runners be better?

Couldve sent the manifold to a machine shop and ask them to deck it I dont get why people do the water entry and exit on the same side, just let it cross flow you want to take heat out. When you reverse the flow you just tranferring heat into metal

I didn’t catch how you finished the 3D printer injector inlets/ports. Do you mind sharing?

you think that TB is gonna be big enough?

the belt sander will get it flat like the earth. its good enough lol 🤪

What tap handle is that?

Subscribed and thank you this is some great content, just curious why the rotary?

😂 don’t @ me bro 😎

I'm not sure about metal 3D printing but I do all the FDM printing at my work and you get a much more accurate finished product when you export and slice the model as a .st(e)p vs a .stl. I'm using Inventor and Prusaslicer. The end of this is what I'm talking about. kzfaq.info/get/bejne/iJZ-hs-DvK6weIU.html

for reference, in case you're not sure what it is kzfaq.info/get/bejne/bKyCgrqWx7yvmnk.htmlsi=EHWBTGDbHKjlv6Fw&t=148

That throttle body looks like it belongs on a 1.8 four-cylinder engine… or is it just the camera making it look small? 🤔 Hhhmmm you did say 68mm. Why so small?

E32 @ 4:52 ?