Ford F-150 EcoBoost Intercooler Pipes 2011-2014

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As the old cliché goes, some things just go together like peas in a pod. Peanut butter and jelly. Cold beer and tailgates. Intercoolers and intercooler pipes; you just can't have one without the other. If you followed along with our 2011-14 F-150 EcoBoost intercooler thread, you've probably been waiting for an update on our intercooler pipes for a while now. Well, the wait is over.

Fabrication

In the last post, fabrication ended for our prototype cold-side pipe. Since then, we've been busy fabricating the hot-side piping and testing. Steve and Mike whipped up a hot-side prototype using the same process as the cold-side piping. Steve started by measuring the stock pipes using our ROMER CMM (coordinate mapping machine). Mike then used those measurements to cut and weld a set of prototype pipes.

The two pipes feeding the intercooler air from the twin-turbos are long and intricate, so proper measurements are

Having already obtained precise dimensions from the factory piping and our test vehicle, our engineering team has begun the arduous, but rewarding process of developing and fabricating intercooler piping for our '11-14 F-150.

Cold-Side Intercooler Pipe Fabrication

Fabricating the cold side appears to be less of a challenge than dealing with the hot side, so we decided to start there to get the ball rolling. Following the path of the factory piping, we began fabrication at the intercooler side of the pipe and worked our way up toward the throttle body.

Ford F-150 EcoBoost intercooler pipe fabrication

Ford F-150 EcoBoost intercooler pipe fabrication

Obtaining the perfect angle required some trial and error, as well as repeated test fitting - as you might imagine, the path of this piping is precise, and we need to be highly accurate in order to ensure fitment will be good among all of the trucks on the road.

After having finished the first portion of our two-piece cold-side pipe, we

Along with creating an awesome intercooler for the EcoBoost (EB), we also want to improve upon the pathways through which air travels to and from the charge air cooler. This will involve replacing factory components that route from the turbocharger to the intercooler and from the intercooler to the throttle body with engineered aluminum pieces.

Factory Ford F-150 EcoBoost Intercooler Piping

The factory piping setup on the F-150 is essentially a rat's nest of molded plastic and rubber couplers that, evident upon removal, is complemented by an internal coating of oil. No wonder catch cans are so popular for these trucks!

Our engineers felt like teenagers again with all of the oil on their skin as they removed the piping in order to inspect each piece, keeping in mind that they would need to replicate all connection points to ensure that our piping is a bolt-on setup.

Check out the cold-side pipe, below.

Factory F-150 intercooler piping

This pipe routes from the single intercooler outlet up