Audi S1 quattro
The client came to us wanting to create a bespoke inlet manifold for his Quattro S1 replica. He already had the CNC’d head flange in-hand, but wanted to know what his options were for the rest of the manifold. The original design intent was to utilise off-the-shelf extruded runners & inlet trumpets, with sheet metal being used to fabricate the rest of the manifold:
The flange was already in-hand & of reasonably sound design, so the main focus of our work here was to
1) Reduce the amount of fabrication time required 2) Reduce manifold sub-component cost
What we came up with was a a cost vs performance compromise. The plenum baseplate was optimised to be cut from a standard 4″ x 3/4″ 6082 T6 aluminium billet. This kept machining time & material wastage to a minimum, but limited the possible inlet port radius. Using one of our trusted suppliers, the part cost for this came in below the import cost of 5 x inlet trumpets from the USA.