Designing an Intake for 5-axis CNC in CAD | K20/K24 Swap Intake Manifold Design  

Glad to hear it!

Of course Rhein! Send me a note support@caducator.com

i'll see if i can't add something. A combination of the form made plenum and the 5x cnc runners is the way to go for sure if you are going to 3d print it. I have heard of 3d printed aluminum and inconel "in-use" plenum pieces, but I don't personally know of any 3d printed plastic manifolds on boost that have survived. You might consider wrapping a layer or two of CF cloth on the outside to help it survive the pressure. I think the biggest issue is the bonding at the layer lines, but there are solutions you can dip it in or spray it with to try and help, but that is likely the failure point.

@@LearnEverythingAboutDesign Thanks for the reply! I will use the CNC kitchen inserts for threads and planing on having some CF cloths and resin layers on the outside and maybe even the inside to keep it all together! Since the car doesn't build a lot of boost, usually works between 1-2bar I will try to see if it can work for me. I'm building a formula 4 with a ea827 8v engine, should be fun!

@@ver.motorsports Sounds awesome. also 2 bar not a lot of boost? 30psi? :) i think of low boost as 7-10 ;) I have used melt in inserts on prints before but never under pressure. You might consider just some sleeves and run a bolt/nut through the runners and plenum flange. Be more of a pain for assembly but you don't have to worry about pull-out issues with the inserts. You can even have a washer flange laser cut to help spread the load out.

@@LearnEverythingAboutDesign Thanks for all the tips, I really appreciate it. I can get water jet cut parts where I live, laser cut is harder to find. That sleeve idea is great didn't even thought about it, thanks! Well for this kind of engines 15-30psi is considered low boost for forged applications. Today the faster 2 ea827 engines are running 7 to 8 bar in a FWD configuration for drag racing in brasil. (I'm from Uruguay) so about 3-4bar is normal in ea827 (AP) engines with ethanol

@@ver.motorsports WOW, sounds like i need one of those engines in my life lol :) Yeah you find a lot of plastic manifolds(injection molded) will have metal sleeves where the bolts are to prevent crushing the plastic to preserve the seal. Waterjet is good too. Laser generally has a better edge finish if the hardness/temper of the material isn't an issue. Other than the boost i think one of your big challenges will be maintaining a seal between the two parts. Off hand i don't know what the transition temp is of the CF/Nylon material. If you use epoxy resin and a layer of cloth on the inside its probably not an issue at normal temps. If you want to chat about this more or join the discord channel send me an email support@caducator.com super interesting project!