Result:

Consistent performance and proper engine response under load.

Solution:

Reworked geometry and routing to maintain ~370mm runner length within tight constraints.

Challenge:
Fit a properly sized header into a restricted engine bay without compromising runner length.

Custom Exhaust Header

Result:
The manifolds turned out to be as compact as possible, allowing the engine to be removed without taking them off. The manifolds have a small heat-generating surface area, which means less heat builds up under the hood. They operate effortlessly on 1,000-horsepower engines.

Solution:
Using 3D scanning and 3D modeling, exhaust manifolds were designed, and their parts were subsequently 3D-printed in metal.

Challenge:
Swapping an LS7 engine into the compact under-the-hood space of a Nissan 400Z. Due to limited space, we needed to design a compact, high-performance exhaust manifold that would not interfere with the steering column or other engine components.

Custom Exhaust Header

Result:
Two V6 engines were installed in the boat, and they performed exceptionally well at high RPMs. The engine does not experience hydraulic shock, and the lambda sensors are functioning properly.

Solution:
Design an exhaust manifold with a double-walled interior to cool the hot exhaust gases.

Challenge:
Manufacture water-cooled exhaust manifolds. Install them under the engine mount in the boat to reduce heat buildup in the engine compartment. Prevent water hammer in the engine when it drops below the water level.

Exhaust Manifold

Result:
The qualification weld was successfully prepared for radiographic (RT/X-Ray) examination and destructive weld testing, demonstrating compliance with the quality standards required for industrial oil and gas applications.

Solution:
Performed GTAW (TIG) welding on AISI 321 stainless steel pipe (Ø76×7 mm) using ER316LSi filler metal, internal argon purging, and controlled welding parameters. The procedure was executed to ensure full penetration, weld integrity, and consistent root quality suitable for radiographic inspection.

Challenge:
Produce a qualification weld joint capable of meeting the requirements for company certification in the oil and gas sector, including non-destructive and destructive testing.

Qualification Weld Test for Oil & Gas Industry