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Why Ford had to 3D Print Ken Block's 914 hp Hoonitruck Intake Manifold

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To make 914 hp, the Gymkhana 1977 Ford F150 Hoonitruck needs A LOT of air for the turbos feeding the 3.5 L EcoBoost V6. Ford's custom designed manifold ended up being too intricate to cast, so Ford Germany put to use one of the most advanced 3D Printers and even that one was pushing the envelope to get the job done. The result? A high flow, lightweight, 3D printed custom manifold that's the largest 3D printed metal part on a functional car, according to Ford. Watch to see how it was designed and how long it takes to print just one, plus why Ken Block picked a 1977 F150.


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