Twisted
Designing a Custom LT1 V8 Engine Cover
Impact: xxxxx
Brief
Replace the standard off-the-shelf Chevrolet LT1 V8 engine cover with something worthy of Twisted’s obsessive attention to detail, and find a manufacturing route that works for low production volumes.
Services
Product Design, Prototyping, Supply Chain Support
Deliverables
Product Design, Prototyping, Supply Chain Support
“Twisted have bold ambitions to become the global leader in customising Land Rover Defenders. Whilst we have some capacity in-house we needed to work with an organisation who can push the boundaries, apply breathtaking innovation and practical engineering experience. Pd-m are cognitive thought leaders and practical designers who have the unique ability to convert concepts into commercially viable solutions.”
Case Study
Twisted Automotive have been redefining the Land Rover Defender for over 20 years — nothing escapes their scrutiny, even parts hidden under the bonnet. When their new LT1 V8 with 8-speed automatic was ready to go, the standard engine cover just didn’t fit the brief.
Our Approach
With volumes too low for injection moulding, we explored vacuum casting, vacuum forming, and 3D printing. After weighing cost, finish, and durability in a feasibility matrix, we landed on CNC-machining solid FRP as the best route.
Reverse Engineering to Perfect Fit
We started by reverse-engineering the stock cover, then sketched out aesthetics and branding placement to align with Twisted’s minimalist design language. A 1:1 FDM-printed prototype gave both teams a chance to see and handle the new design before committing.
Multiple iterations later, we had a fit that was millimetre-perfect, with full clearance in the engine bay.
Prototyping
The first production-quality CNC-machined cover went straight into real-world testing, and the results were spot on. The first production run is now complete, with covers custom-painted to match each customer’s Defender.
Our role extended beyond design, we helped Twisted set up the manufacturing and supply chain process so they can order new covers seamlessly as needed.
The result
A refined, functional, and brand-aligned engine cover that reflects Twisted’s ethos: making the best, better.