Engineering

GOAL: Create a direct-fit performance intercooler that outperforms the stock intercooler.

RESULTS: The Mishimoto manifold outflowed and outperformed the stock intake manifold while decreasing the pressure drop through the manifold. The Mishimoto manifold is more reliable than the factory manifold by replacing the crimped-on intercooler core with a fully welded aluminum core. In addition, the Mishimoto core is approximately 33% larger than stock and flowed up to 15% better than the stock manifold.

CONCLUSION: The Mishimoto intercooler kit is a great upgrade for those looking for more power and reliability for their S58-powered BMW.

Design Objectives:

-Create an intercooler that performs better than the stock intercooler

-The intercooler must give the customer the ability to add port fuel injection and port nitrous injection. *

-The intercooler/manifold must not increase pressure loss through the system.

We all know how the saying goes. “If it ain’t broke, don’t fix it.” Like any overutilized cliché, there’s some truth to it. It wouldn’t have assimilated into our lexicon if it wasn’t, right? The same sentiment rings true for Nissan’s Z-cars. These sporty coupes don’t change much between generations, but we can help but adore them. The latest generation is no exception to this trend. Nissan upcycled many of the primary aspects of the latest Z. From the retro styling, the 370Z DNA underpinning the chassis, and the VR30DDTT nestled under the characteristically long hood, we’ve seen these designs before. To some, it may seem like a parts bin model, but we all know this concoction results in a new, exciting car packed with potential. Potential that we already have the plan to unlock.

What makes for a successful off-roader? Sure, a powerplant sending loads of low-end grunt to all four grippy all-terrain tires combined with a high-rising and flexible suspension are all essential to the success of any overlander, but that’s not necessarily the secret sauce. Durability is the key. Nothing spoils the euphoria of cruising through gorgeous landscapes in your Bronco, quite like a trail obstacle jumping out and viciously assaulting your undercarriage. While most of the critical bits under your Bronco are already well protected, the rear suspension is still left defenseless against the menacing wilderness. Well, defenseless until now.

What makes a car so alluring? Sure retro-modern styling combined with a power-hungry powerplant draw you in, but what keeps you in the driver’s seat? Consistency. Sports cars like the Z are intended for those with a lead foot and a need for speed, so keeping things consistently cool is imperative. Let’s face it. There’s no worse torture to an enthusiast than having to feather the throttle on their high-strung sports car because of looming high temperatures. Nissan knows this, and while they did their best to set the Z up for intercooling success, the heat exchanger still needs an overhaul for what we enthusiasts have in store.

It’s old news now that the VB WRX is a much more grown up, and civilized version of its former rally-racing self. Now days, the minimal frills road ready racecar has been replaced with a modest, creature comfort laden, family oriented sporty sedan. Now, we’re not saying there’s anything wrong with wanting to be comfortable with a dash of performance, but we all know this civilized look for the WRX is just a façade. Underneath that new “dad bod” is the same rowdy rally-inspired AWD sedan that’s a magnet for modification, and nothing helps turbo mods stick better quite like an upgraded intercooler.

Much like society would crumble without a robust infrastructure, BMW’s pinnacle compact sports sedan becomes a pretty driveway decoration without the proper supporting hardware. The heavy-hitting S58 under the hood that moves the world-class suspension relies on a complex network of coolant lines and air channels that keep that twin-turbo straight six operating at peak performance. BMW may be known for their exquisite engineering prowess in their vehicles, yet some of the supporting infrastructure needs revision, especially regarding the charge pipes.

As the age-old adage goes, “measure twice and cut once.” This sentiment applies to any undertaking, from massive infrastructure renovations to DIY projects. This mentality is essential when it comes to updating the boost channels through the G8X’s engine bay.

Proper fitment is critical for any component we engineer, but it’s particularly vital when snaking a redesigned charge pipe around the S58’s perimeter. It’s a tight fit under the M3’s hood, and our engineering team needed to ensure that our larger charge pipe wasn’t encroaching on other systems or components in the crowded engine bay. So, to triple-check our fitment, we brought our design to life.

It’s no secret that the Bronco is a capable off-roader right off Ford’s assembly line. During its absence from the roads and trails, Ford bolstered both the platform and the available options to solidify the Bronco at the top of the off-roading food chain. While any Bronco option is a strong choice, these vehicles are only as strong as their weakest link. In this case, the chink in the Bronco’s armor comes from the coolant expansion tank, but we already have a solution.

BMW’s G8X platform is already as close as possible to the ideal combination of form and function. The heralded benchmark of performance sports sedans is designed to tackle blistering track times while keeping you in absolute comfort. It’s as close to perfect of a driving experience as you can get right off the factory floor. While we’ve already made improvements to this platform with our intake design, we can still move closer to achieving automotive Zen.

Most would jump at the chance to relive their rambunctious youth and dive back into those nostalgic core memories that have turned into lively stories with old friends. Some, though, would be harder to convince, like the VB WRX. This former Scandi-flicking, boxer-growling, rally racing bad-boy has turned grown-up family man and is content with leaving that lifestyle behind. We like to think that we’re pretty convincing, though, and feel we can entice that rally-racer inspiration out with the help of a new intake.

Our negotiations kick off with the start of our prototype. With our design plans solidified in our last post, we dove straight into bringing the preliminary versions of this intake to life right here in the R&D facility.