When Cory Taulbert of Taulbert Chassis Components reached out to Hoosier Pattern to work be apart of this project, we didn’t realize how cool the results would be! Hoosier Pattern’s 3D sand printers created molds for an intake manifold that ended up being a part of a Cadillac V8 rebuild.
Bill Ganahl (South City Rod and Custom) is currently building a hot rod for client Mark Warrick. The 1936 Ford 3 window coupe hosts an immense amount of subtle custom touches, something South City Rod and Custom is known for. Under the hood sits a 1955 Cadillac V8.
Engine conversions were very common in the early days of hot rodding, as it offered the owner an easy way to get more power as Detroit rolled out better engines. In parallel, the aftermarket quickly supported the new engines with custom camshafts, multiple carburetor intakes, and even supercharger systems.
A company called Supecharger Company of Turin (SCoT) sold superchargers of various displacements for popular engines, but more importantly, produced the intake manifolds that allowed everything to be bolted together. Fast forward to today, some of these parts are still around but the original limited-production has made those parts extremely rare today.
Back to Mark’s 1936 Ford – he wanted to put a SCoT supercharger on the Cadillac V8. Bill had the tall task of locating an original SCoT intake to put the package together, but there were none to be found (that were for sale anyway). Bill turned to a friend, Cory Taulbert, to see what they could come up with.
Cory suggested that they make a new intake manifold. This would allow them to custom tailor it to Mark’s car, as well as give Mark the exclusivity to unique “one-off” part. Cory offered up the CAD services and got to work designing a new intake manifold, with inspiration from the original SCoT intake manifold.
When it came time to actually make it, Cory reached out to Hoosier Pattern. He had recently seen a friend working on a 1920’s Packard Indy Car engine block, that was created from scratch. Hoosier Pattern 3D printed the molds, so it was clear that it was the place to go to.
At Hoosier, Todd Yoder worked with the 3D model to develop the 3D printed molds. The molds were then shipped to Crystyl Engineering in Piqua, OH, where an aluminum casting was poured and heated treated. To finished off the casting, Tooling Science Inc in Maple Grove, MN finish machined the interfacing surfaces and flanges.
It’s always very exciting to see a project that we were a part of come together in the end and even better when we get to share these projects with the rest of the industry. The possibilities with the 3D sand printers at Hoosier Pattern are truly endless. Need a quote for a project that requires 3D printed sand? Go here.
Every year Hoosier Pattern enjoys taking in internships, externships, or job shadowers, and this summer we had Clay Barlow in the shop with us! Clay has been with us all summer throughout different areas of the shop. Learn more about Clay's experience in his own words below.
Purdue University - West Lafayette, Junior in the fall of 2020 and I am majoring in Materials Science and Engineering
What made you seek out Hoosier Pattern as a place to work at for the summer?
It was an opportunity to work within my area of interest for the first time. Not only that, but it looked like and proved to be true that Hoosier Pattern is a place that does a lot of things and does them all well. Also, they are consistently innovating and are leading their industry. I was excited long before I arrived and I wasn't disappointed.
What types of things did you do at Hoosier Pattern?
I've been able to do a lot and got experience within every department over the course of my internship. My main role was to work on improving the 3D plastic printing capabilities, but I also worked with machining, sand printing, and on other projects.
What did you enjoy about working at Hoosier Pattern?
I enjoyed that there is never a dull day and that each day, each hour, you will be working on something different. Not only that, but it seems like Hoosier Pattern is focused on continuously improving all parts of the company and to be a part of that type of innovation is awesome. Last but not least, it's a very friendly, almost family-like, atmosphere. You have a lot of responsibility and freedom to get things done and if you happen to mess up, the people here are nothing but supportive and helpful to fix the problem.
What were some memorable projects you got to work on and participate in?
3D printer optimization: I got to dial in the printer and slice parameters to begin producing carbon fiber infused plastic parts. I also got to work on integrating soluble support into our parts to improve support removal and surface quality.
Centrifugal ISO-Finishing Inquiry: I produced a part in 4 materials to explore a new
Casting made from a sand printed mold: I got to design apart from a print and then had the mold sand printed and got to pour molten aluminum into it to create a casting. (pictured above)
What do you want to do as a career? DO you think that working at Hoosier Pattern during the summer will help you decide on what you want to do as a career?
I am hoping to land in the foundry or at least in the wider metals production industry. working at Hoosier Pattern has already helped me with career decisions by solidifying it in my mind and allowing me to gain an extracurricular real-life experience within the industry. I also got to see another side of the casting world.
Other than the job itself, what kind of things has Hoosier Pattern taught you?
While at Hoosier Pattern, I've learned a lot about being a better professional, engineer, and person. Outside of the job skills, I learned a lot about managing multiple projects at once and making sure goals get met in a timely manner. I learned better ways to communicate, especially across the company and outside of the company. just in talking with the others in my workspace, I got info on professional networking, on the foundry industry, and on things completely outside of work like general life skills and advice.
Outside of work, what do you enjoy doing? What organizations are you involved in at school? Do you play sports?
I enjoy cooking, spending time outside, tinkering, and making stuff and hanging out with friends and family. At school, I'm mainly involved as a leader in volunteering and professional organizations including Purdue's chapters of American Foundry Society and Material Advantage. as for sports, I'll play football or basketball with friends or run and lift also.
Clay's last day at Hoosier Pattern will be this Friday, August 14th. Good luck at Purdue this fall, Clay!