It’s been a minute and the manifold is just about ready.
The 3D printed aluminum parts include the intercooler end caps, intercooler wedge, Porsche badge, and intake flanges.
After the plastic failed I went with printed aluminum flanges that are bonded to the intake with a large overlapping area. The intercooler end caps are bonded to the cores using DP420. The cores with end caps are then bonded into the cartridge assembly using MA8110.
Overall the design got pretty complex as it developed. Not ideal, but I work to keep things very stout. I’m feeling good about it.
Next step is the finish and paint it. I’ll used a textured black.
