Lotus Elan

Inverting mold material

PostPost by: h20hamelan » Fri Jan 14, 2022 4:29 pm

I am swapping a +2 Élan Twin Cam, for a Duratec. The problem is, intake manifolds are not available. Sure I will need to make my own, but… Cosworth has done the research already, so I dont need to reinvent the wheel, but… intake is facing the wrong way, and will need to pass through the firewall.

My simple solution would be to buy a Cossie knock off, take a mold, then figure out how to invert it.
There are no 3D scanners close to here that I can find. Or this would be a simple solution.

What I suspect, is someone here knows of a nylon or plastic which once set, can be turned inside out. So a 2 piece mold. Maybe something like a kid “crazy carpet” for tobogganing. Because it is flexible, and rigid. But of course I dont know the exact polymer chain, so this will be difficult If not impossible.
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PostPost by: nmauduit » Fri Jan 14, 2022 5:12 pm

I've seen header prototyping kits that seemed quite tempting to play with (a bit like lego), if only for the price...

https://www.trick-tools.com/Icengineworks-Exhaust-Header-Modeling-Systems-864?view_all (no affiliation)

for a one off and not needing to be formula one accurate, even if you want to make a fancy titanium one someone, you could always prototype with mild steel for cheaper I suppose...
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PostPost by: JohnCh » Fri Jan 14, 2022 5:50 pm

h20hamelan wrote:I am swapping a +2 Élan Twin Cam, for a Duratec. The problem is, intake manifolds are not available..


Have you considered Jenvey throttle bodies? They have direct to head units for the Duratec that include the intake runners and provide more options on air feed. I've run these on my Westfield for years and am using their 2.5L versions for my new project. They have the added benefit of sounding like Webers :D

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PostPost by: h20hamelan » Fri Jan 14, 2022 6:10 pm

Hi, thanks!
Yes, considered both. Wanting to use single throttle body, car is not for me or I would have gone Jenvey. Car is for my brother and I need to keep it simple for him. Not that there should be more issues with Jenvey, I figure Cosworth has it dialed.
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PostPost by: h20hamelan » Fri Jan 14, 2022 6:35 pm

I see there are apps for 3D scanning
Maybe problem solved

https://www.google.ca/search?q=ipad+3d+ ... ent=safari
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PostPost by: h20hamelan » Sat Jan 15, 2022 1:30 am

Found a local (100 miles away), with a large 3D printer.
So off to the races I am!
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PostPost by: h20hamelan » Sat Jan 15, 2022 3:50 am

https://www.youtube.com/watch?v=-mY-M3UQggw

Fibre reinforced printable nylon
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