High Road – 2021+ Ford Bronco Performance Intercooler R&D, Part 7 – 2.7L Dyno Testing

High Road – 2021+ Ford Bronco Performance Intercooler R&D, Part 7 – 2.7L Dyno Testing

The 2.7L Bronco is a true adventure machine. No matter the trim or configuration, these twin-turbo V6-powered Broncos are determined to get you to any destination, no matter what’s in their way. Well, for the most part. Unfortunately, the intercooler keeping the charged air from those turbos cool isn’t exactly up to the task, and it’s in the way of more pertinent off-roading gear. So, to retain the 2.7L’s sheer determination, we had some better ideas for the intercooler, and now it’s time to see how they perform. 

In our last post, our 2.3L powered Base model, aka Pedro, was taking point through the tribulations of dyno testing, with our 2.7L following close behind. While these Broncos are headed to the same destination, their route is slightly different. Specifically, where our manual shifting 2.3L used the path of the DynaPacks, our 10-speed automatic equipped 2.7L found its way to our DynoJet system. So while these dynos operate differently, we still perform the same gambit of testing for both platforms. 

To refresh those who just came from Pedro’s expedition in our last post, our intercooling testing consists of two parts. The first is individual power pulls that provide us with slices of the intercooler’s performance for extrapolation. We then simulate the absolute worst conditions possible to put our design through its most grueling test. For both stages, we’re comparing the cooling power of our design against the OEM intercooler and the effect that it has on the vehicle’s performance. 

To refresh those who just came from Pedro’s expedition in our last post, our intercooling testing consists of two parts. The first is individual power pulls that provide us with slices of the intercooler’s performance for extrapolation. We then simulate the absolute worst conditions possible to put our design through its most grueling test. For both stages, we’re comparing the cooling power of our design against the OEM intercooler and the effect that it has on the vehicle’s performance. To refresh those who just came from Pedro’s expedition in our last post, our intercooling testing consists of two parts. The first is individual power pulls that provide us with slices of the intercooler’s performance for extrapolation. We then simulate the absolute worst conditions possible to put our design through its most grueling test. For both stages, we’re comparing the cooling power of our design against the OEM intercooler and the effect that it has on the vehicle’s performance. 

Now we turn up the heat. Our heat soak test is specifically designed to fill the intercooler with as much heat as possible by stacking up to 6 back-to-back runs together without a cooldown period. As the inlet temperatures rise, we can gauge the real-world cooling performance from the outlet temperatures. Specifically, our high-mounted intercooler maintained a 20°F lower temperature than the stock unit during this torture test. 

Charged air cooling is an intercooler’s primary task, providing a solid base to build more power on any forced induction platform. Bolt-on power to a factory-tuned vehicle isn’t expected, but it’s often the beneficial side effect of improved flow and cooler air. Our design’s benefit to the system did just that, and we recorded max power gains of 8HP and 10TQ on our stock-tuned 2.7L Bronco. 

Adventure is what the Bronco is designed to deliver. The conglomeration of systems are stoked for those jaunts off the asphalt and into the great unknown. The intercooler, on the other hand, is a bit of a homebody. It’s overwhelmed by hard work and open spaces, so we’re leaving it where it’s comfortable and adding a new member to the team. With our intercooler installed, the 2.7L is filled with determination and is back to its confident self, ready to whisk you away on the next expedition. Make sure that you stay tuned for info on how to get yours, coming soon!

Thanks for Reading!

-Nick