Page 3 - Ford

The right gear is essential to any adventure. This, in turn, makes any adventure the perfect excuse to upgrade your load-out, and who doesn't like to have the latest and greatest equipment? The same could be said about the rig that promises adventure-ready status at all times. While Ford made sure to load these Broncos out with a diverse arsenal of off-roading bits, there were some aspects that we still needed that excuse to upgrade.

Just needing to move a component to clear space for more off-roading equipment is one best excuses to upgrade your systems, and we devised just the thing. This high-mounted intercooler is ideal for those looking to hide a winch or plotting to improve the Bronco's approach angle. Now that it's in the shop, we're stoked to show off this intercooler's final design and rehome it behind the upper grille.

The Bronco rolled back into relevance on a high horse. During the decades-long hiatus from the streets and trails, Ford had ample time to plot their domination of the off-roader market, and so far, it seems to be going to plan. From towering tires to sophisticated trail cameras and everything in between, these Broncos roll off the assembly line fully prepared to dominate any obstacle that gets in their way. However, as well equipped as these wild machines are, even the most prepared adventurer can find themselves tumbling from that high horse, so adding layers of protection is ideal.

One of the best means of protecting your Bronco from the trials and tribulations of the great outdoors is with a snorkel. But with all of the protective measures integrated into the Bronco's design, how would raising the EcoBoost's induction point keep the engine internals safe? Well, we're glad you asked!

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There's a beauty in simplicity, especially in the automotive realm. In an age where cars practically pilot themselves, the lack of features and frills puts some character back into the driving experience. Our 2.3L Bronco is a prime example of this. Sporting almost no options from the factory other than standard equipment, this baby Bronco left enough of an impression on us here that it's one of the few vehicles in Mishimoto history to be given a name. Pedro looks great in steel wheels, but this plucky off-roader is still a blank canvas for plenty more modification.

Our intake followed a similar design path based on the simplicity of this base Bronco's accouterments. On the surface, Pedro might look run-of-the-mill, but that's only skin deep. The 2.3L under the hood is packing plenty of high-tech features,

While piling into your Explorer ST for a long haul, it's tough not to have that cliché mantra running through your head - It's more about the journey than the destination. However, we here at Mishimoto think that saying depends on the context. We, enthusiasts, are quickly intoxicated by the ST's 3.0 EcoBoost powerplant and easily hypnotized by the surprisingly nimble chassis' ability to tackle the curvey backroads, making us prefer to savor the trip. When it comes to the journey of building that speed machine, however, things become much more destination-focused. While that journey is necessary, we're much more eager for the result. In the quest for more power, though, a pit stop at the intercooler is required to reach your final destination.

Improving intercooler designs is a delicate balancing act between flow and core density. Both of these aspects are vital to improving the system's performance, but they have reciprocating results on each other. An ultra-dense core may shrug

The Bronco is built for the wilderness. Just a glance at this towering machine makes that apparent. Even the trims not dressed to the nines in the sprawling catalog of off-roading accouterments still have the natural instinct to scamper through most terrains thanks to the well-sorted AWD system and 2.7L powerplant. While this twin-turbo V6 is no slouch, we enthusiasts still have the inherent need to add even more horses to the pack. Cranking up the boost through tunes and turbos is the simplest solution, but other components must be addressed to handle this added power first.

Ford's priority for function becomes truly apparent once you lift the hood on your 2.7L powered Bronco. The intricate maze of tubes and pipes on full display gives us flashbacks to that classic

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It's no secret that the Bronco wasn't resurrected to break land speed records. Just one look at this brick on towering off-roading tires makes it apparent that this machine was destined for more wild pathways. No matter where these Broncos feel at home, more power is still a necessity both on the trail and for the commute to work. Luckily, Ford stuffed different iterations of their platform that's become synonymous with power potential - the EcoBoost. Whether it's the 2.3L or the 2.7L, these engines have plenty of surplus performance locked away that can be accessed with the correct key. In this case, that key is intercooler shaped.

Strengthening any system is never quite complete without at least a dry run. Careful planning and consideration could all come crashing down if these concepts can't quite hack it in the real world. Preliminary tests and prototypes are essential to this process to ensure all plans fit properly into place, which is exactly what we're aiming to test.

The restrictive OEM pipes immediately dash any plans for big boost, but things could be even worse if our expansion plans don't properly fit in the already tight engine bay. While our sophisticated modeling software does provide a precise digital workshop, nothing quite beats physically installing the design on the vehicle. So, to triple-check our work, we created a pair of 3D printed prototype pipes to confirm fitment before starting production of the real thing.

Advances in technology worked wonders for the internal combustion engine. With every new vehicle launched, there's a list of advancements to these controlled-explosion contraptions to harness maximum power and efficiency while keeping emissions in check. It's no secret that Ford doused their reinvented Bronco in these same innovations, but even this new-school hardware still falls victim to old-school by-products, like blow-by.

No matter the installed innovations, blow-by still remains the age-old nemesis of any engine's top-end components. The mix of fuel and oil vapors galvanize into stubborn carbon buildup, robbing the 2.7L of the power and efficiency the Ford engineers painstakingly worked into this engine. Yes, this engine utilizes a dual-injection system that will mitigate carbon buildup, but even port-injection vehicles suffer the same symptoms of unfiltered blow-by over time. So, even with factory-installed countermeasures, a catch can setup is still one of the best means of

Preparation and reinforcement are essential when any system is about to experience a sudden increase in volume. Whether it's the website holding the info for the resurrected legendary off-roading lineup, the production line bolting these trucks together for the mountains of orders, or the piping system in the 2.3L that just had a performance tune installed, solidifying these systems is crucial to a smooth and optimized operation. Like with any forced induction engine, the four-cylinder Broncos' intercooling system holds the key to a significant portion of that power potential you're after. However, the stock piping still needs some work before cranking up the boost.

There are plenty of reasons to need some extra grunt from your 2.3L EcoBoost, with the stock pipes standing in the way of the enormous potential this engine packs. Luckily our engineer, Dan, is already on the case to unlock the 2.3L's performance, but first, we need to look at what needs to be improved from Ford's design.