V6 Engine Twin Turbo Manifold Design

About the project

i want to design turbo manifold for V6 type engine. so it will be two manifold design with slight differences in orientation. Manifold to cylinder head flange will be 3 separate pieces or they can be connected to each other. turbo side will have V-band flange. i'm planning to 3D Print those manifolds, or make them myself inhouse depends on design. i would like to know what am i looking at roughly to make two 3 cylinder manifold design. giving you rough idea of looks. i will provide Scan of engine and scan of actual turbochargers so you can do fitment and alignment https://drive.google.com/file/d/1vRJbqGk3ogc9SylS1wmal4AwZFUlWcsy/view?usp=drive_link, https://drive.google.com/file/d/1WJXyXx4HmSwWpVP0o-bCVLa36IvpQaQN/view?usp=drive_link, https://drive.google.com/file/d/1IfuitlBPsC9O55arMZNjnL56q2Ir3qXK/view?usp=drive_link, https://drive.google.com/file/d/1JnIT8X6Qx44lNOYKNktDz2x7SmBU7New/view?usp=drive_link Keep in mind we will start with manifolds but there are other components needed such as intake pipe, charge pipe, downpipe design but this is different scope. So i’d rather do all together with one person so while you will be designing exhaust manifold for turbo you keep in mind routing direction of pipes Twin Turbo CAD Design Brief Design a complete OEM-style twin turbo system for the supplied V6 engine using the provided 3D scans. The goal is to fit larger aftermarket turbos within the same physical envelope as the factory setup, allowing the complete system to install like OEM with minimal modifications. Reference Files * Engine 3D scan * OEM turbo scans * Aftermarket turbo scans * Exhaust gasket scan * Flange measurements * OEM intake, charge pipe and downpipe scans Use these files as the primary reference. Turbo Placement * Keep both turbos in the OEM location. * Design around the supplied aftermarket turbos only. * No mirror-image turbo option is available. * Internal wastegates must be retained. * Prefer keeping the supplied turbo orientation. If proper intake/charge pipe routing cannot be achieved, the turbo may be re-clocked and new wastegate actuator brackets can be designed. Exhaust Manifolds Design one manifold for each cylinder bank. Requirements: * Organic metal 3D-printable design. * V-band turbo connection. * Equal runner lengths where practical. * Smooth runner transitions. * Maximize flow while staying within OEM packaging. * Leave adequate clearance for surrounding components. * Design for manufacturability. Cylinder Head Flanges * Final design should use 3 separate flanges (one per exhaust port), similar to OEM. * Connected flanges are only acceptable for prototype fitment checks. * Reinforce the flange design. * Use all 4 available cylinder head mounting bolts per exhaust port instead of the OEM 2-bolt arrangement for improved rigidity and sealing. Future Project Scope The manifolds are only Phase 1. Please design them with the following future components in mind so everything fits together without redesigning the manifolds later: * Turbo inlet pipes * Charge pipes * Downpipes * Wastegate routing (if required) The manifold layout should leave sufficient room for practical routing of all intake and exhaust components while maintaining OEM-like serviceability and packaging. Design Priorities 1. OEM turbo location. 2. Keep supplied turbo orientation if possible. 3. OEM-style fitment and serviceability. 4. Proper clearance for future intake, charge pipe and exhaust routing. 5. Minimize additional brackets and fabrication. Deliverables * Native CAD files * STEP files * STL files * Manufacturing-ready models

Skills required