AUTOSPORT HISTORICS
28 25 JULY 2019 AUTOSPORT HISTORICS
t’s no surprise that historic racing often relies on
traditional techniques. Even with the increasing level
of competition, some old crafts, such as fabricating
and panel beating, remain crucial. But modern
approaches can also play an important role.
KW Heritage, which was offi cially launched in 2018, is the
classic vehicle engineering division of high-performance
engineering company KW Special Projects. It aims to use
cutting-edge technology to help restore and maintain
historic machinery and has already been involved in
several motorsport projects.
One of those was to help preparation fi rm Martin Stretton
Racing restore an Alfa Romeo T33/3 sports-racer, and the
project demonstrated some of the key strengths of KWH. The
three-litre V8 engine was in good condition, but the lightweight
magnesium alloy front cover was in a bad way, with several
running repairs to patch up cracks and corrosion having been
made over the years. Finding original parts for rare cars can
often be a problem and so it proved with the Alfa.
“When we were searching for a replacement cover, the
options were limited,” says Martin Stretton. “We found
several alternatives that were close, but none of them
were exact matches. We had to explore other avenues.
“Having investigated the pattern making route, using
Bringing
new solutions
to old problems
I
KW Heritage has only recently joined the historics
arena, but it has already started making a difference
BY KEVIN TURNER
skilled model makers, we realised this would be a technically
diffi cult project to deliver. It would also be prohibitively
expensive [given the low-volume requirements].”
This is where KWH stepped in. Where tooling or drawings
no longer exist, KWH uses a range of 3D scanning techniques
to capture the form of a component.
“We were presented with an engine
cover that was cracked and in a bit of a
mess,” says Edward Smith (right), head
of Heritage engineering. “The need was
to remanufacture the front cover – the
casting that covers the crank sprocket,
cam gears, timing chain etc. It closes
off the front of the engine.”
The original front cover and water-
pump housing were both scanned. But
just getting the basic 3D data into a
CAD programme wasn’t enough.
“While we had the original part to scan,
undertaking a simple like-for-like photocopy operation would
not solve the problem, as the original part we had was defective,”
says Stuart Banyard, KWSP’s head of advanced manufacturing.
“We were able to create a digital scan of the part – and then,
crucially, make vital changes to the design to bring it back to
its original geometry and functionality. Intelligent use of CAD