Observe a BMW expert create a 3D-printable turbo manifold with 1,800 horsepower.

      Couch Built/YouTube

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      After discussing with a 3D designer, I’ve developed a greater admiration for the capabilities of 3D printing custom car components. Today, I came across an intriguing video that showcases the engineering and refinement of custom turbo plumbing using parts that are 3D printed in steel. The surprising part is that these components are far more affordable than one might assume.

      Jon Volk is recognized in the custom BMW community for crafting exhaust manifolds that enthusiasts attach turbos to for significant power gains. His name frequently appears in older forum threads related to E30 and E36 tuning. Recently, he has focused more on digital part engineering and 3D printing through his YouTube channel, Couch Built, where he describes his work as “Building cars, mostly from the couch, using 3D scanning, Fusion360, and some bloody knuckles.” He is also behind the 13B rotary-powered BMW i8 project we covered earlier this year.

      In a new upload, he takes us through the creation of a new exhaust manifold for an exceptionally powerful G80 BMW M3, boasting over 1,000 horsepower and owned by Jordan Horowitz, a notable Bimmer modder with a shop named RK Tunes on Long Island.

      The setup on this M3 is nothing short of amusing; it’s the complete opposite of a sleeper. Couch Built/YouTube

      I was drawn to this video by its "it's cheaper than you thought" aspect, but I found myself engrossed as Volk demonstrated how he optimized the design of the exhaust manifold and the overall plumbing of the turbo kit on his computer. Watching the project come together is truly fascinating.

      Volk illustrates how he arranges and adjusts elements virtually, and instead of sending plans to a fabricator, as was common a few years ago, he simply forwards his designs to a 3D printing company for a quote. In this instance, he is partnered with JLC3DP, which 3D prints everything he designed for around $2,200. This is not merely a plastic prototype; it’s a real, steel turbo kit (excluding the turbo) that is nearly ready for installation upon arrival.

      This cost is comparable to that of a high-quality performance header from a decade ago. However, don't get too excited just yet, as this price does not account for a crucial element—Volk’s time and expertise. The parts were priced at $2,200 because he already knew the necessary shape. If you need to hire someone for the design, that expense will significantly inflate your modification budget—at least until AI is capable of designing an exhaust manifold, which may not be far off.

      Nonetheless, this is still less than what you would have spent on fabrication for something like this in the past. The fact that such single-unit manufacturing is now a possibility is quite impressive.

      Be sure to watch the video detailing the design process, and see how Volk cleaned up the part once it arrived. The clip offers insight into the current advancements in high-end exhaust tuning.

      Horowitz has also released a video regarding the part, which you can view for more context if you’re interested in diving deeper.

      I hold a great appreciation for the engineers and tuners who can fine-tune components like this. I’m just pleased if I can prevent mice from damaging my stock E46.

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