The Mishimoto 2nd-Generation Cummins Intercooler, Part 3: Prototype Evaluation and Test Fit
Interested in picking up our 2nd Gen Cummins intercooler or intercooler pipe kit? Check out the product pages linked below!
Dodge 5.9L Cummins Intercooler
Dodge 5.9L Cummins Intercooler Pipe & Boot Kit
Mishimoto intercooler dyno testing
We included a teaser shot of our prototype cooler toward the end of our last update. Now it is time to provide a more in-depth look at our intercooler.
Mishimoto intercooler prototype
Keep in mind that this prototype is a raw unit, void of any painting or coating. Our end product will be finished with a powder coat in either silver or black.
Mishimoto intercooler prototype
Mishimoto intercooler prototype
Mishimoto intercooler prototype
Check out our bar-and-plate core with some very nice welds!
Mishimoto intercooler prototype core
Mishimoto intercooler prototype welds
We are doing something a bit different with branding on this particular cooler. We decided to cast our company tag line into the driver-side end tank. It's subtle yet identifies the cooler as a Mishimoto product. We dig it!
Mishimoto intercooler prototype end-tank branding
As with the overall finish, this area will be refined to perfect aesthetics on our final product.
Now a look at our inlet design!
Mishimoto intercooler prototype inlet
The shapes of our inlet and outlet are very similar to the factory intercooler, although not nearly as restrictive. Due to the design of the radiator support, these parts of the cooler must be shaped as such to fit. That said, we were able to keep a 3" cross-section for these inlets, which is a massive improvement over the factory tanks. The additional flow is going to make a huge impact on our testing results.
Below is a shot of our brackets that mount the AC condenser to the intercooler core. Unfortunately this heat exchanger is placed in front of the intercooler, which will hide our awesome intercooler once fully installed.
Mishimoto intercooler AC bracket mount
Test Fitting the Mishimoto Prototype
Once again, we brought our test trucks in for some intercooler test fitting. Fitment is very important when designing such a product. No one wants to have to modify a truck or brand new intercooler to get it to fit. We want this cooler to drop into place just like the factory unit.
Test truck in shop
A 12-valve also made its way into our shop, and factory cooler removal began!
24-valve intercooler removal
12-valve intercooler removal
And the installation of our cooler was up next! Check it out.
Mishimoto intercooler installation
This cooler goes in fairly quickly, and our engineers are fairly familiar with the process. After a few hours, we had the coolers installed in both trucks.
Mishimoto intercooler installation
Mishimoto intercooler installation
Here's our cooler fully installed in a 12-valve!
Mishimoto intercooler installed
We are also including a bracketing system to mount the factory AC condenser. Check this piece out!
Mishimoto intercooler AC condenser bracket
Mishimoto intercooler AC condenser bracket
Intercooler Testing
We had a few concerns with obtaining consistent data on our first round of product testing. We are working to solve the issues and gather the data we need to show what this cooler can do for your truck.
Check back in a few weeks with more details on how we did!
Thanks
-John
