Monthly Archives: May 2017

When you're hurtling towards a concrete-walled turn at over 90 MPH, you'd better know that every nut and bolt in your car is torqued to spec.

Photo: Nick Thomas

We've all had to prepare for something before"a date, an interview, a test. It's always a stressful experience. Now imagine you were about to go on a date with somebody you were pretty sure is trying to kill you. Or, imagine that your desk would be pushed off a 100ft cliff if you failed that test. Preparing for a track day is a lot like that.

About a week before our Focus RS was set to tear up Raceway Park's road course, Dan and Eric were neck deep in tasks. We would be pushing the RS to its limits to test our rear differential cooler; every box had to be checked and every part ready. A week isn't a lot of time to install diagnostic equipment, maximize the car's performance, finalize prototypes, and safety check the entire vehicle, but it all had to be done before 6:00 AM on Tuesday.

Before they could start prepping the mechanical,

Our engineering department sought to bombard our intercooler with dyno runs, gathering as much data as possible to ensure that it could stand up to the abuse and intensity you plan to put it through. Due to the fact that this intercooler is sandwiched between the radiator and air conditioning condenser, we had to be sure that our core could effectively combat the effects of heat-soak while performing at maximum efficiency. First, we had to start with size. If the intercooler was going to be an effective modification, it had to be bigger. In case you guys need a refresher from our last update, see below for a size comparison between our core and the factory unit.

Core volume comparison

External fin surface area comparison

We have given the core a boost in several areas, including internal volume by 45%, external fin surface area by a sizeable 239%, and overall core size by 78%. This will allow for much better cooling and heat transfer. While the core is bigger than stock, it will also be

Before you think you're seeing double, yes; we have two catch can projects in the works for Jeep's JK Wrangler, the first one being for the years of 2007-2011. I could have jammed both projects into one long series, but it would just be a disservice to you if I took that easy route.  The more research I've done for this project, the more I realize I'm talking to two, very different markets. I'd rather each project's focus be on that specific model-year Jeep, that way, you know that I am making these blog updates specifically for you 2012+ JK owners. Ok, the cat is out of the bag now - why don't we get into this project?

Our other Jeep has the 3.8L engine

The 3.8L and the 3.6L engines are just two different engines to non-Jeep folk, but you and I both know it goes deeper than that. The 3.6L option puts out an impressive 285hp and 260 lb-ft of torque, which is a substantial power increase from previous models. Even with a snappier engine and a change in gearing, it still looks like Chrysler

Do you know the origin of the term Jeep? Some say that during WWII, these vehicles were referred to as General Purpose vehicles, and soldiers began slurring the acronym, G.P., into Jeep, hence its name today (there's a similar story behind the term Humvee). Others say that the name was derived from the popular cartoon character, Eugene the Jeep, from when the Popeye show aired back in the 1940's. Eugene the Jeep was a "go anywhere, do anything" type character, and interestingly enough, the US government had a contract sent out to several automotive manufacturers requesting a vehicle to replace the horse that was able to go anywhere and do anything. Are we going to try and debunk this once-and-for-all? No, I'm no historian. While there is still a lot of background I can go into there, this is a blog about awesome vehicle product development, so let's get to it.

We already know that the Jeep name is synonymous with utility. Their notoriety soared for being the go-to service vehicle during

When I last left off our engineer, Steve, was busy scanning and creating a 3D model of the F30 stock unit as a reference for our new design. There is an impressive amount of engineering that has gone into this intercooler project already, with more to come. One of the reasons for this attention to detail is because of the wide range of models that this new cooler is going to fit, as seen by our photo gallery. Another reason is because BMW has a pesky habit of living up to their moniker, "The Ultimate Driving Machine," they leave little room for error.

Steve working the Faro Design ScanArm to create a 3D model of the stock intercooler unit.

I've always been a huge fan of BMW, especially when it comes to the meticulous engineering that goes into each of their vehicles. Every model they put out is designed to last. Whether it be a 28-year old 3-series speeding around the flat back roads of New Jersey, or the much bigger and heavier X3 taking on the winding mountain roads of the Colorado

The section of I95 between Baltimore and Philadelphia might seem like drab and uninspired stretch of pavement for the millions of commuters and travelers getting from point A to point B. However, it  serves as the main artery for bringing together people every year in a celebrated event to scarf down the savory staple of Philadelphia's culinary prowess, the cheesesteak. It's not just any group of people, but rather an extensive faction of gear-heads piloting the best vehicles that Germany, England, Japan, and America have to offer to satisfy their craving for speed and the fine mixture of cheese wiz and steak. What caused this yearly pilgrimage to South Philly's very own Tony Luke's cheesesteak stand? Simply one man who found Bimmers and cheesesteaks belonged together, and clearly others shared his appreciation for the combo before finally the event took its current form.

The Euro Cheesesteak Run's organizer Chris Walsh waits to enter the lot on Oregon Ave. in Philadelphia outside of

Usually, the first noticeable change people make to any car is how it sounds. As summer starts to heat up, some of us gearheads are starting to take our unicorns, endless money-pits, kind-of-finished projects, or whatever you call your ride, out of storage, or the garage. It's the season for nightly meets, hot track days and long cruises, giving you the perfect opportunity to showcase the changes you've made to your pride and joy since you put it away for the winter. Whether you replaced your catalytic converter with a high flow version, got a full, larger-diameter exhaust, or custom fabricated your own straight-pipe setup, the exhaust is the go-to modification if you want to be heard.

We know that there is a sweet middle ground many go for when modifying the exhaust. An exhaust that is too tame can be a bit of a let-down if you want some serious growl. However, an exhaust that is too aggressive can anger the neighbors, attract Johnny Law, and loudly drone on the highway - none of which