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This article represents the experiences encountered by Ford Motor Company Product Engineering while trying to define a viable method for reverse engineering an exhaust manifold. The intent of this investigation was to develop a reverse engineering technique that would result in the generation of a CAD math model so that current CAE tools, such as FEA, could be applied to analyze current production exhaust manifold designs which have no CAD data base. Investigation into the various types of reverse engineering tools available lead Product Engineering to investigate an X-ray scan or computed tomography (CT) technique. The article focuses on how this X-ray scan or computed tomography (CT) technique was successfully applied to the development of exhaust manifolds.