Engine swaps break the aftermarket. The moment a Gen 4 Coyote goes into a 1st generation Bronco, the catalog stops having answers — and everything from the header flange to the air filter has to be engineered rather than ordered.
The Challenge
This 1st-generation Ford Bronco was built around a Gen 4 Coyote engine swap, which meant options for a bolt-on header or intake solution were slim to nonexistent. The project came through Brockett Built on behalf of Classic Ford Broncos, who needed both systems engineered from the ground up — not adapted, not modified, designed.
The Process
Exhaust
Campsite Precision designed a full modular header system and crossover pipe, merging to a custom dual X-pipe and cat-back run all the way to the tailpipe. Brockett Built handled the metal fabrication. Designing the header system as modular was deliberate — it makes the system serviceable and repeatable rather than a one-off that can never be built again.
Intake
I fully 3D-scanned the engine bay and designed a custom intake system from the ground up: a laser-etched acrylic cover, an MJF 3D-printed intake tube, and custom mounting hardware. Every component was test-printed for fit before a supplier-made prototype was built — catching interference in a cheap printed part rather than in an expensive finished one.
Campsite Precision designed and produced the intake system in-house while leveraging domestic manufacturing partners for the MJF additive process. That combination keeps design control in one place while still producing parts at real production quality.
The Result
A production-ready intake system, with Classic Ford Broncos planning to order in recurring batches — which is the difference between a one-off custom part and an actual product line. Alongside it, a fully custom exhaust system built for an engine swap with minimal existing aftermarket support.
Project Snapshot
- Client: Brockett Built, on behalf of Classic Ford Broncos
- Platform: 1st Gen Ford Bronco, Gen 4 Coyote swap
- Services: 3D scanning, CAD design, prototyping, low-volume production
- Scope: Modular header system, crossover pipe, dual X-pipe, cat-back exhaust, custom intake system
- Turnaround: 3D scan to prototype build in 12 days
- Outcome: Recurring production batches
"I've worked with Campsite Precision on just about everything that leaves my shop worth talking about. I'm a fabricator — I know what I want a part to do, but turning a rough idea into precise, production-ready CAD is where they come in. Their 3D scanning and reverse engineering mean fitment is dead-on the first time instead of me cutting, checking, and re-cutting. They engineered both of my production shop tools with me, and they've been behind full builds too, including complete Bronco exhaust systems. Campsite Precision lets a small shop punch way above its weight — the design side is handled and handled right, so I can focus on building. If you need real engineering that actually understands fabrication, these are the people."
Marcus Brockett
Owner, Brockett Built
Building Something the Catalog Doesn't Cover?
Swaps, one-offs, and discontinued platforms are where scan-to-CAD earns its keep. Request a project quote and tell me what you're building.
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