The problem
The prototype manifold fitted, but the customer needed a batch of thirty that matched it — the same port transition, the same bolt pattern, and the same black finish over a bead blasted surface.
What we did
The prototype was machined from solid with the flange faces and bolt pattern established in the first operation, then the runners opened from both ends so the port transitions blend. Because the prototype process was already the production process, the batch repeated the geometry rather than approximating it.
The anodizing sample from the prototype was kept as the colour reference, and the batch was processed against it over the same bead blast media.
Result
The batch bolted to the head without slotting, the finish matched the approved sample, and the sealing faces were reported with the shipment so the customer could check the assembly fit before installing.