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:

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:

Runner lengths were balanced within a 4 mm range (436–440 mm), allowing the fabrication process to begin with a validated design rather than trial-and-error.

Solution:

Designed the system digitally, developed a custom 3-into-1 merge collector, and validated runner geometry before fabrication. The build utilized custom 3D-printed components integrated into the final welded assembly.

Challenge:
Package a performance-oriented naturally aspirated header while maintaining equal runner lengths in a highly constrained engine bay.

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