Twin Turbo Sterrato

Rear Fascia Laser Scanning

This Sterrato's rear bumper grille became a roadblock for the mounting of the Boost Logic twin turbo system. Reduced airflow and interruption of the visual intent of the build were not an option, It came out. That left a gap in the rear fascia that needed a proper answer, not a workaround.

A filler piece was designed to close it cleanly — shaped to the existing body lines, printed in PET-GF, and fitted without modification.

The larger scope of this project is to design an intake system to re-integrate the factory roof scoop intake into custom sealed airboxes fitted to the Boost Logic twin turbo kit.

3d Modeling

The filler panel modelled in CAD from the scan data before going to print. Shaped to follow the rear fascia and close out the gap left by the grille delete. The 3d curvature of each surface makes this a perfect use case for scanning and printing,

3D scanning and CAD makes a job like this viable in the first place. Shaping a piece like this by hand to fit a complex body line accurately would be a serious fabrication undertaking — the technology turns it into a design problem instead.

THe ALTRD Process

This type of project is not meant as a permanent solution. Once the intake system project is underway the whole rear bumper will be revisited. For now it keeps the build looking intentional rather than leaving an unfinished gap where the grille used to be.