Metal Sculpt

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Capalaba, QLD
Metal Sculpt

Custom automotive fabrication and performance workshop based in Capalaba QLD

www.metalsculpt.com.au

05/09/2026

Another R&D project from the last couple of weeks has been designing a 3D printed turbo manifold for the FD3S! Designed this using a scan of our jig, so the wastegates and flanges end up in the same location as our fabricated units.

Having the round 13B exhaust port transition to the T4 profiles over the length of the runner is ideal, and having the wastegates integrated saves hours of fabrication time.

We've found a number of unavoidable issues with printing the entire manifold from 316L stainless, and won't be offering a complete stainless 3D printed unit at this point. Many interesting lessons learnt this week which I'll share over the coming days 😊

02/09/2026

FB Rx-7 rear exhaust section jigged up! A very satisfying jig to construct, especially the twin tip locating fixture which we made by bead-rolling dual 2 1/4" tubes for a slip fit.

The systems will be available with either Xforce or AES mufflers, and either twin 2.5" or single 3.5" dumped tips as shown. Constructed completely from 304 stainless steel... validating the jig is next, followed by the mid pipes.

31/08/2026

Next step in our FD3S V-mount installation was designing a cold air intake 👌 very happy with how this turned out!

This features a 4" intake tube with a two piece design, and places the air filter into an ideal location in the bumper. Serviceability will be a breeze, only 5 fasteners to undo the lid. The lower pipe will be connected inside the airbox using a silicone joiner. The backing plate was designed using the 3D scan to completely seal off the hot manifold area.

Test print went well, some minor revisions have been made to improve fitment... fitting V2 in the morning after an overnight print, then more metal 3D printing!

26/08/2026

FD3S V-mount intercooler install completed! Very happy with how this turned out. All 3D printed components fit up perfectly with zero modifications needed.

The intercooler fits well, it's shroud tucks easily over the bonnet latch. The turbo compressor housing can be removed with the intercooler in place, and the outlet location and angle is an exact match of the CAD model.

Next up for this build is more 3D scanning and modelling: We will be designing the 4" air intake, twin 12" thermofan shroud, and ducting to seal off the cores to the front bumper. For everyone asking, these kits will be available for purchase after we're satisfied with the testing.

25/08/2026

Metal 3D printed intake assembly is here for Jakz' FD3S Rx-7 build! We took on the challenge to design and print this entire V-mount system from aluminium.

This gave us the ability to achieve geometry that would be impossible using traditional fabrication techniques:

-Hot side end tank has two internal splitters to distribute flow evenly over the Garrett - Advancing Motion core
-Cold side end tank has an internal bell-mouth for better flow on the outlet
-The cold side piping transitions from 3" to 3.5" over the entire length of the tube, rather than using a reducer
-Zero welding required besides the HDi intercooler clamps = no internal turbulence from pipes butting together at weld joints

Beyond excited to get this together. Stay tuned for updates.

23/08/2026

First set of FB Rx-7 headers manufactured using our purpose built jig 👌 fitment test passed on the development car, meaning these now have the tick of approval to be fabricated and shipped worldwide with guaranteed fitment.

A range of options for ceramic coating and additional sensor bungs will be on the available through the website. Next step is finishing our development of the mid and rear sections, hopefully this coming week!

22/08/2026

FB RX-7 licence plate holders are back in stock, one of our most popular products. We designed these as direct replacements for the OEM brackets after they were discontinued by Mazda.

This is the last batch we'll be selling at our current price of $135AUD. Once the current stock is gone, pricing will increase to $165AUD.

Front, AUS/UK rear and USA rear versions are all currently available.

Available now through our website while stock lasts.

18/08/2026

A neat little jig made up for the FB Rx-7 2" stainless headers from our previous post. Bolt patterns are drilled to suit both 12A and 13B cars, we will also be adding provisions for EGT and 02 sensors on each runner.

The next step is to make an identical set using the jig, then test fit them on the car to validate our manufacturing process 😊

14/08/2026

2" stainless headers made up for Luke's Series 3 Rx-7! CAD designed using a 3D scan for optimum fitment and flow. A very special car to me, having owned multiple first gen Rx-7s over the last 15 years 😊

Working on the jig for these next, followed by the rest of the exhaust. Very excited to offer a complete bolt on system! Will update the website when these are available.

12/08/2026

Turbo back exhaust system finished up for Tyler's Series 2 Rx-7 👌

We ran this system in 3" stainless steel, using the best rotary mufflers from Matthew Davis. Topped off nicely with a lobster cut exhaust tip and 2" screamer pipe. Next stop is off to the dyno to make some numbers!

Address

Shed 4/82 Redland Bay Road
Capalaba, QLD
4157

Website

http://metalsculpt.com.au/

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