MANUFACTURING
Exhaust Headers
The exhaust headers were assembled using a sheet metal jig. After assembly, a standard set of U and J bends were cut on the bandsaw and profiled to fit the CAD and jig requirements. Upon arrangement, they were tacked and welded using Tungsten Inert Gas (TIG) Arc Welding.
Swirl-Pot
The swirl pot is made of an Aluminum tube that is cut on the bandsaw. Holes are drilled on the sides for the BMRS line fittings. The bottom surface for the swirl pot is waterjetted and is then welded onto the Aluminum tube. The fittings for the pipe (AN3) are then profiled such that there is no restriction to the flow of water through the water lines.
Intake Manifold
The intake-manifold is 3D printed using SLS. It is 3D printed as 6 parts plus a restrictor that is required by SAE rules to limit the amount of air entering the engine. These parts are joined together using DP-460.
The throttle pedal bracket (in white) was 3D printed using SLS. The pedal was made using Carbon Fiber while the bushings and the shafts were machined using Aluminum 6061. The Pedal Stop was made by welding a square piece of Mild Steel of 0.0625" thickness onto a Bolt. The entire pedal is bolted to the monocoque using AN3 bolts.
