Ford Performance Shows How They 3D-Printed Hoonitruck’s Intake Manifold

The Hoonitruck is easily one of 2018’s most special builds, as it combines Ken Block’s love affair with Ford pickup trucks with outrageous specs. The devil, however, is in the details, and more specifically at the gorgeous aluminum intake manifold that sits proudly on top of the twin turbo V6.

Ford Performance engineers worked together with a team of research engineers in Europe in designing the part and conducting structural analysis. With the help of RWTH Aachen’s Digital Additive Production Institute in Germany, the team was able to 3D-print a very intricate aluminum intake manifold that sends air from the turbos to the cylinders.

3D printing (also known as additive manufacturing) offers significant design flexibility, helping in improving performance and reducing weight. The whole process of building the Hoonitruck’s manifold took five days, with the finished part weighing almost 6 kg (13.2lbs).

“We are fortunate to have access to incredible technology, but this was one project that pushed us – and our computing power – to the absolute limit. The manifold has a complex, web‑like structure that couldn’t be made using traditional manufacturing methods. We ended up dissolving the support systems in acid,” said Raphael Koch, engineer, Advanced Materials and Processes, Ford of Europe.

“I think Ford did an exceptional job. This is my favorite part of the ‘Hoonitruck’. You could not have made it any other way,” said Ken Block.

The Hoonitruck is powered by a modified twin-turbo 3.5-liter V6 Ecoboost from the Ford GT Le Mans racer, producing an immense 914 HP and 702lb-ft of peak torque. Its custom body is made out of military-grade aluminum and it even has a trailer hitch that was put in good use during the latest Gymkhana Ten video.

 

more photos...
Trump Administration Preparing To Freeze Fuel Efficiency Penalties

Under the Obama administration, fines would have almost tripled for cars that didn’t meet fuel efficiency standards.

Illegal Immigrants Hitch A Ride In Ferrari F1 Truck Heading To Britain

Ferrari discovered the two immigrants when unloading a truck at the Silverstone circuit.

2020 Corvette C8 Will Debut As A Stingray, Check Out Its New Logos

Chevrolet hasn’t changed just the position of the engine in the new ‘Vette; the logos and lettering are new too.

Tesla Roadster’s SpaceX Thrusters To Be Hidden Under License Plate

The Tesla Roadster was meant to launch in 2020 but probably won’t arrive until 2021.

New Toyota Supra FASTER On Top Gear’s Test Track Than Lambo Murcielago

Let the new Toyota Supra GT grow on you as the Stig drives it on the Top Gear test track.

Does Cupra’s Frankfurt Concept Preview Next-Gen Leon Hot Hatch?

The video is not very revealing yet it shows a sleek silhouette that could preview the upcoming Cupra Leon.

2020 Honda Insight Priced From $22,930, Gets More Standard Safety Kit

The 2020 Honda Insight will begin arriving at dealerships nationwide starting July 16.

James May Opens Up About The Time He Got Fired From Autocar

Way before Top Gear became his job, James May was fired from one of UK’s biggest motoring magazines and this is why.

C8 Corvette’s Twin-Turbo LT7 V8 To Use Same Architecture As Cadillac’s ‘Blackwing’

The future Chevrolet C8 Corvette will use this engine, inevitably with over 650 hp.

Re-Watch Sebastian Vettel Taking Out Verstappen At Silverstone

Ferrari’s Sebastian Vettel apologized to Max Verstappen immediately after the British Grand Prix.