Here is the rewritten article:
Stephan Papadakis and his team were on a mission to build a Toyota Supra that would produce over 1,000 horsepower. To achieve this feat, they needed a custom intake manifold that could work in harmony with their engine setup.
However, creating such a manifold from scratch was no easy task. They couldn't just get it off the shelf or design it without testing its feasibility. So, what they did was laser scan the original intake manifold to create an accurate digital model of it.
Using computer-aided design (CAD) software, they then designed the intake manifold in 3D, taking into account the specific requirements of their engine setup. This CAD model was then 3D printed on a metal printer to test fit it on the actual engine.
The process of selective laser melting (SLM) allowed them to build the intake manifold layer by layer, using a thin layer of metal powder that was fused together with a laser. This additive process made it possible to create complex geometries and internal structures that would be difficult or impossible to achieve with traditional manufacturing methods.
The resulting plenum for the intake took over 51 hours to make, requiring the printer to build 6,991 layers of metal powder. Because the intake was large and had to be broken up into multiple pieces, which were then welded together to form a single piece.
Despite the engineering challenges involved, Stephan Papadakis' team successfully created a custom intake manifold that worked flawlessly with their Supra's engine setup.
In an interview, Papadakis shared his passion for motorsports and his love of seeing the vehicles themselves and how they're built. He wished that racing teams would share more about their engineering and design processes, which could be applied to everyday cars.
The team's effort in creating a custom intake manifold was featured on a YouTube video, where they went into great detail about the process involved. Papadakis' channel has some amazing content, including his Supra build, which is definitely worth checking out.
And finally, don't forget to check out James' new show, "The D-List", which airs on Fridays!
WEBVTTKind: captionsLanguage: enThanks the last pastor sponsoring a portion of the vi deoThis is the world's first1000 horsepower2020 Supra and it's still using the stock engineWhy is that so surprising well when this car came out people thought the engine was absolute trashSo why is this one with relatively limited modifications able to make a thousand horsepower?Well, it comes down to this man Stefan Papadakis and his mad scientist level of ingenuity in today's episodeWe're going to go into how stefan disassembled this engine and rebuilt it from the ground upWe're gonna look at how we use forged parts and why the process of forging is so importantwe'll see the reason why so many stock parts were actually worth keeping andhow they stood up to that amount of horsepower and finally my favorite we're gonna look at how he used lasers and3d printed metal parts to push this engine over the edge you can 3d print metal. I didn't know that and that's super coolSo get ready. Oh boy. IDid why would I do that? I got a saveIs that a Supra?Thanks the last pass for sponsoring this portion of the video if you're as obsessed with JDM cars as meyou're probably on a million different forms and websites and all those passwords and usernames get so confusing but IUse LastPass so I can keep all of those in one place LastPassremembers and auto fills your passwords on websites and in apps on Android and iOSThey make it super convenient to just Bop around and not have to worry aboutOh, is this the password for it where I put a number on the end or where I put an exclamation pointNone of that LastPass has unlimitedpassword storage free cross-device sync andPassword sharing which comes in handy when my homeboys want to hop on the 5g trinkClick the link and start using LastPass todayThanks to LastPass for sponsoring that part ofBut not this one. So why did Stephan Papadakis is keep the german-born engine that comes in the Supra?Well because he loves a good engineering challenge nowIf you don't know who Papadakis is this guy is an absolute legend in the 90s at only 21 years oldHe built the first tube chassis front-wheel drive drag car in the United StatesThe dude has put a NASCAR motor in a ScionHe's built some wild-ass cars with some impressive enginesand now he wanted to get a thousand horsepower out of the hated stock super engine theB-58, so, where do you start?Well first you needed to know what it was really capable of so he did what any sensibleEfficient race team owner slash car builder would do he took a brand new2020 Supra with 500 miles on it and he took it apartDisassembling it down to the bare block and by taking it apartHe could inspect each critical component to determine its high horsepower worthy kind of like a crime-sceneinvestigator for engine he'd use his skills to 1figure out how to get more horsepower out of the b-58 powerplantand two, what any of the stock components be capable of handling a thousand horsepower also as a side noteHe was the first person to document doing this thingI mean this engine was so new that he had to call in favors to his friends overseasto get certain tools to take it apart and not only that he didn't have some shop manual orYouTube to help him out. This was a massive challengeThis dude is straight up organ trailing his way through the b-58 engineAnyways when your goal is to get a thousand horsepower, how do you get there?Alright so first let's talk about how you get more power just overall in general we could start off with our most favorite ofequations the donut equationWhich is more air plus more fuel equals more power and we're gonna focus on the more airVariable now the amount of air getting into your engine is the rate limiting factor in our famed donut equationYou can sit there and you can argue with meAnd you say hey Jeremiah fuel is also a limiting factorbut I tell you you're gonna run out of air before you run out of the ability to dump more fuel in there and thenYou're gonna lose the conversation. It'll look like a nerd so don't do itSo there are a few ways we can get more air into the motor but one way is to increase the displacementMeaning we can increase the volume of our cylinder so we can do that by boring the cylinders which is making them widerlike thatOr we can do it by stroking the engine by changing out the crankshaftAnd that makes a cylinder taller like that that allows the piston to travel down the cylinder further and thereforeIncreasing the volume of air it pulls in a Papadakis he didn't go this route and he didn't for a few good reasonsFrom the factory the all-aluminum d-58 cylinder walls are coated with an electricWhy're spring and that process?starts out with aconductive metal wire that they then heat up until its melting point and then they take that melted wire and they spray it on thecylinder walls using high pressure and once it's sprayed on it forms a very thin layer of iron material about0.3 millimeters thick and this layer is extremelywear resistant transfers heat really goodAnd it reduces the amount of friction on the piston ringsNow if you were to going for that cylinder, you'd essentially be removing that layer and that's not goodSo what about stroking a motor? Well when Papadakis dismantled the engine. He took a good CSILook at the crankshaft and it was a beefy one. Not only was it beefyIt was forged and I'm gonna get into forts parts and explain why that's important in a secondBut for now, let's just know that there wasn't a need to swap out the crank just yetSo if we didn't bore it or Stroke it to get more air into the cylinders. What did he do?Well another way we can add more air is by using forced induction systemsWe can supercharge it or we can turbocharger hashtag blue escapes now both of these methods force more airInto the cylinders and the b-58 already comes turbocharged. So that's greatBut the stock turbocharger can't deliver the amount of air mass needed to make a thousand horsepowerYou need a bigger turbo to force more air in so Papa. Doc Asst went with the biggest turboBorgWarner makes capable of flowing a hundred and ten pounds of air a minuteWhen it's spinning at its max rpm of a hundred and seventeenThousand rpm now to give you an idea of how much air that is sayWe had a room that's 10 foot wide by 10 foot tall by 10 foot longIt could suck all thousand cubic feet out of that room in 41 secondsthat's a lotta air but slapping a bigger turbo on the b-58 creates a bunch more stress on theinternal components of that engine and when we say internals we're talking aboutPistons rods the crank the camshafts the bearingsAnything that has a force applied to itDuring the combustion cycle now if we add in more air and we added more fuel. We create a much bigger. Boomexplosioninside the combustion chamber the cylindersright and that bigger combustion pushes the piston down with a bunch more force and if we're going from335 horsepower which the stock engine has2,000 horsepower almost three times as much we can assume the forces acting on those internal componentsIt's also three times as much. So how do you make sure those internals can hold up to all that added horsepower?Well, you make them out of a stronger material and here is where we'll talk about forged internalsNow there are a lot of ways you can go about making metal partsBut today I'm gonna focus on casting parts and forging partsso firstlet's talk about the most common way of making parts and that isCasting so casting is a process in which you take a metal and then you heat it up until it turns it to liquidYou then pour that liquid metal into a mold that's in the shape of your partAnd then let that metal cool inside the mold where it solidifiesTurns from a liquid to solid and now you have your part. So there are three main ways of casting partsThere's sand casting which uses a mold from sandthere's investment casting which uses a plaster mold and there's die casting which uses high pressure to form your part in betweenMetal dies and the main principle throughout all those methods is really the same you heat up a metalYou pour it in a mold and you let it coolAnd by the way humans have been casting parts for thousands of yearsone of the oldest surviving cast parts is a copula frog from3200 BC all the way from Mesopotamia nowWe still cast a lot of parts today not only in the automotive world, but it things like your cooking pansWe got tools actually. Let me grab a toolThese are pipe wrenches that are cast and they're really cheaply madeThey even say china stamped on it and they're a piece of shitI've broken like five of these there is a ton of stuff madeusing the casting process and there's a few reasons why you can castextremely large parts or parts with complicated shapes you use casting when you need a part made out of a specific out word you canyou're molten metals and you can mix them together to achieve theSpecific ratio of metal you need in your final part and when you're trying to cut down on costsonce you have the mold made you can essentially duplicate your part much quicker casting is a great way to pump out a lot ofIdentical parts cool that's gasso what is forging well instead of heating metal until it melts like in casting you start off with asolid piece of metal and you shape it using pressure and that pressure comes from a hammer old-school style or apneumatic power hammer or a die which we typically useNowadays and even like casting there are a bunch of different waysYou can Forge parts and the reason it's calledforging is because when you heat the metal up you use a forge to do so and the most simplistic of terms aForge is just a really really hot ovenNow you might have seen on TV swords being made. They're made using the forging process the blacksmithHe'll be like hammering down on the sword putting it in a forge till it gets hot pulling it back outHammering it again and reshaping the blade blacksmith are friggin coolMan welders and blacksmiths tuff some so when gearhead say their engine has forged internalsWe all nod our head and were like yeah cool cool, manYeah, that must be a good thing and it is a good thing. But why is the forging process?Better than the casting process. Well, it comes down to grain structure. We're nerding out today boysGet ready nowIf we were to take a piece of iron for example and put it under a high-powered microscopeWe can see that it has a crystalline structure meaning those iron atoms. Have a very highly orderedArrangement and when metals fail is when those atoms slip against each otherSo when you cast apart, for exampleThe liquid metal has a grain structure that goes in all sorts of different directions and that is not goodBecause now you have a part with non-uniform strength propertiesalsothere's always a possibility when you cast parts that you create internal voids due to gas pockets your point liquid metal in andAir can get trapped in between the metal and then as it solidifiesYou now have a pocket of air in the middle of your part. That means different areas of the partWe'll have different densities which is bad because now as the part cools it can warpWeakening the entire part as a whole so with forged parts, you're not heating up your metal until it liquefiesWhich means you're not introducing air pockets into your part the grain those metal atoms?Maintain their crystalline structure throughout the entire part its uniform and that is very very goodEspecially in parts that are experiencing high amounts of stress because the grain has a uniform orientationIt has a higher impact strength and more resistance to fatigue. So not only our fourth part strongerIt takes more time to make them the quality of the starting material is usually better and thereforeIt's more expensive to make them. So what does all this have to do with this Supra?Well when you're adding extra boost from the bigger turboThere's a few weak links in your engine when you apply that amount of excess forceTalking about the Pistons the rods and the head gasketso if this engine is making a thousand horsepower, that means each cylinder is making about866 horsepower that is a lot of horsepower out of one cylinderThat's more horsepower than the entire engine in a 2020 Corolla. I mean what the heck that's also a lot of pressureNot only pushing down on the piston, but pushing back up on the headThere's a bunch of forces trying to rip these parts apartso they need to be made out of a stronger material and that's why this1000 horsepower Supra used forged internalsNow the forged pistons were specificallyDesigned for this car and they have coatings on the top and on the side skirtsAnd the top coating is put on there to help resist heat on the Dome of the piston and the coating on the skirtsHelp reduce the wear on the cylinder bores and the rods they were designed specifically for this motor using43:30 pre hardened chromoly steelForging if you're curious what that number means good because I'm gonna tell youCarbon and alloy steels use a standardizedfour-digit number to classify the type of steel and the first two digits tell you the main type of material so43 tells us that it's a nickel chromium molybdenum steel and the last two digitsThey tell you the amount of carbon present in the steel and hundreds of a percent by weightSo thirty means it's point three zero percent weight carbon and that's all very good and coolYou can impress your friends with it. But if you take anything away from this is that these are extremely well-madeForged parts now to keep the head on tightRemember, we have a lot more cylinder pressure now from the added boostThey needed special ARP studs which allowed the head bolts to be torqued down to?135Foot-pounds that means with the 12 inch ratchet like thisYou have to put a hundred and thirty-five pounds of pressure to torque those bolts average weight of a 12 year old probably135 freaking pounds happy y'all watching this can't even lift 135 poundswe can I know y'all just at home watching videos do some push-ups that leads me to my next point and that is thesurprising amount of stock internals used in this buildI mean, it uses the stock head gasketThe stock cams the stock crankshaft to stock piston rings even the stock rod in main burns the engineers over at ToyotaBMW engineered the factory engine to be able to withstand a lot of horsepower New Age2jz anybody maybe I don't know. I'm kind of saying it I'm saying it is I'm saying it's betterI'm fine in the comments. Come find me at my house. Well a verbal lashing tjs to jay-z's better. No no way, broB-58 better come convince me all dude. You're so lucky. I can't come over there and whoop beer. Oh, you're luckyI can't come over there. Whoop your IWant to talk about a few of those stock partsSpecifically the head gasket the bearings and the piston rings because to be honest. I think it is quite amazingThey were able to use those parts now firstLet's talk about the head gasket of a head gasketFunction is to create a seal in between the engine block and the cylinder head and you may have heard of peopleblowing head gaskets right to understand why that happens we need to talk aboutCompression ratios no compression ratios are actually pretty easy to understand if you have your cylinder, right?Yep, and there's a certain amount of volume in that cylinderwellA compression ratio is basically the volume of that cylinder when the piston is way down here and then as the piston compressesAll that volume of air there's a little gap at the topSo it's the ratio of the volume when the piston is down hereso when the piston is at the very top typically it's in the range of7 to 1 8 to 1 and high horsepower and race motors that are running off race fuelIt's in the 10 and a half to 11 to 1 ratioBut at the end of the day all that you need to know. Is that that number?Determines what kind and what type of head gasket you can use so we use this fancy fun equationWe find out our final compression ratioIt's 39 to 1 and remember that's not only the pressure pushing down on the pistonBut pushing up on the cylinder headSo you need a head gasket that can keep the seal between the head and the block when that pressureIs that hot and in the case of this 2020 Supra they can use the stock head gasketWhich is pretty crazy giving that this engine is putting out40 pounds of boost to make that thousand horsepowerThere are a bunch of factors going to blowing a head gasket a bad tune endingYour air fuel mixture is off too much heat pre-ignition, etc, etcSo a high compression ratio isn't the only driving factor, but regardless you need a high-qualityhead gasket in the stock one is thatThe next stock internal on the list are the rod and the main bearings and an internal combustion engine the connecting rodsThey're attached at one end to the piston on the other end. They're attached to the crankshaftAnd then your crankshaft itself is attached to the blockSo the rod bearings those are the bearings placed in between the rod and the crankshaft and the main bearingsThose are placed in between the crankshaft and the block and in the case of this2020 Supra those bearings have a special coating and the reason they have a special coating is because of the start/stop functionThat comes standard when you buy a Supra now a lot of cars nowadays have this start/stop functionPull up to a red light and your car shuts offWell when this happens, there's no oil being pumped to coat those bearingsNow this phenomena happens all the time in cars without this stop start functionBut it's not as big of a deal over the life of the engine because you're not turning it on and offMultiple times during your commute to work for exampleBut in cars with this feature it obviously happens a lot more and those bearings are nowExperiencing more friction and more wear because they're lacking that oilso to combat this these bearings are coded in the2020s supra uses a polymer coated bearing that not only improves the wear resistantIt increases the fatigue strengthCompared to non coated bearings and that is great when you're building a high horsepower motor like the one in this carNow the last stock component I want to talk about are the rings and if you look at a pistonThere are grooves that the Rings are retaining and it's the rings that are actually inContact with the cylinder wall on a four-stroke engine. There are three types of rings you have your compression ringYou have your wiper ring and you have an oil ring and each of those rings serves a specificFunction if we start at the bottom of our piston closest to the skirt, that is the oil ringThe oil ring is used to remove excess oil from the cylinder wallLet's get all the oil gets splashed up from underneath the crank returning that oilusing return holes that are in the bottom groove of thePiston now above that of oil ring is the wiper ring and its main function is also to remove some excess oil from the cylinderThere like squeeze use finally on top of that is the compression ring and that keeps the pressureConfined in the cylinder and also it's the job of all three rings to transfer heat from the pistonTo the cylinder walls and when you make more horsepowerYou're creating more heat and the ability of these rings to withstand that heat and added compression isReally important to keeping a healthy engine nowThis has been just a very long-winded way of saying the internals on the Supra areReally really goodNot too many engines out there can use the stock crank cans head gasket piston rings rod and main bearings in their searchfor a thousand horsepowerBut there's one thing in particular that Papadakis needed to bypass that was stock and that is the directInjection system. So in our doughnut equation, we've already talked about air now. We're going to talk about fuelNow in a more conventionalFuel injection system that fuel sprayed into the intake port or the manifold and then that fuel is then pulled into the combustion chamberAlong with the air passing by the intake valve on its way to the combustion chamber now with direct injectionThe fuel doesn't go by the intake valves, it goes straight into the cylinder. And the reason we have direct injection is pretty coolReally, it improves combustion efficiencyIt increases fuel economy and it lowers the amount of emissions your car make so direct injection is actually really coolBut unfortunately for Papadakis the aftermarket support for the 2020 supra direct injectors is not there right nowHe needs to be able to dump a bunch more fuel through them and be able to control them and no one makes a systemThat can do that. So he had to go with a more traditionalsetup using fuel injectors placed in the intake manifold six2000 CC fuel injectors to be exact and because the super uses direct injection the factory intake manifolddoesn't have any ports for those injectors to go in so acompletely new intake manifold neededRedesigned and built and this was maybe the scariest part of the entire build to get a thousand horsepowerThey needed this manifold to work if they couldn't get it, right. They weren't going to hit their mark of making a thousand horsepowerSo what they did is they laser scanned the original intake manifoldThey then took thatScan and they put it into CAD software and they designed it wrong it in 3d printed that CAD model to test fit it onthe actual engine and then they finally3d printed the intake manifold usingAluminum, that's right. You get 3d print metal people. We're living in the freakin future. This is so coolSo, how do you print metal? Well, you use lasers, it's always lasers guys lasers fix everythingIt's a process called selective laser melting and it's really cool and fundamentallyIt's pretty easy to understand now first. You start off with a 3d model, right?And then you take that 3d part and you section it into thousands of shooty layers thousands of cross-sectionsAnd this is an additive processSo it's going to build that part one cross section one layer at a timeNow inside an SL n machine you have a chamber that's filled with metal powderAnd that metal powder is spread across a base plate in a very thin layer about two oneThousands of an inch thick of metal powder. That's about half the size of a human hair. Just think about dust youJust dusting putting just on top of a metal plate, right, but it's metal dustOkay a laser inside the machine then fuses that thin layer of metal powderSitting on the base plate in the shape of your first two dimensional layerNow the bill plate drops down and a layer of metal powder is then evenly laid across the top of the first layer the laserthen comes by and it fuses the second layer powder on top of the first and a process repeats itself until you have all ofThose 2d layers all of those 2dCross-sections built up to make a 3d part now just the plenum for the intake was made out of sixThousand nine hundred and ninety-one layers that took over51 hours to make and because the intake was so large and had to be broken up into multiple piecesWhere it was then welded together to form a single piece. This is by far the coolestPart on this car and what's even cooler is that it worked?I mean it was a huge engineering challenge and they were able to successfully make itThat's the best part whenever you're engineer or something and it works out greatNo, and that speaks to who Papadakis is and why he did this build in the first place hear it from the man himselfSo for me, I I love motorsportsBut it's not always about the driver and the championship and the car is going around the track and seeing who's winningI really love to seethe vehicles themselves and how they're built and wish the teams on the highest level that Formula One andNASCAR and such would share more ofhow the cars are engineered and builtto reallySee a lot of thatYou know ingenuity that goes into those and then potentially even take some of what we can learn fromThem sharing on their race cars and apply to the cars that we builtWe want to thank Stephan Papadakis for giving us a bunch of his time to talk about the Supra as well as @jonsibalWho designed the body kit on the Supra and the render reused throughout the video? Thank you. Thank you so muchIt's really great stuff and we only dove into a fraction of this buildIf you haven't already go to his YouTube page where he goes in-depthI'm not just the engine but the roll cage the suspension setup anything and everything you could imagineHe has some seriously great content on there all of us that don't have watched his videosThey are really really great go support him too. And then dude. We got donut every day of the week nowJames has got a new show. It's called the d-list. Check it out that's on FridaysClick like subscribe and we here at bumper-to-bumperWe actually need your helpIf you want your car's footage to be featured on this showFollow us on all our social media accounts will be putting messages out there letting you knowWhich cars we'll be featuring on the show in future episodesAnd then you could possibly see your car on an episode of bumper to bumper. So follow usSend me a messageIf you got a car that you want to see on the show that's got a cool engineering aspect to it. Bye for nowOh boy, IDidn't why would I do that? I gotta say is that as Supra and then do the thing, right? What in?