Subaru WRX Top-Mount Intercooler 2015+

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

As noted in our previous post, we decided to design a shroud that would channel airflow more efficiently through the core of our intercooler. Because our cooler features a larger footprint, the stock air shroud directs flow to only a portion of the core. Opening up this airflow to the entire core should result in even greater temperature reductions than we saw during our first round of testing.

Stock Intercooler Shroud

First, let's take a look at the stock shroud as Steve removes it from our test vehicle. Here is what you will see under the hood of your WRX.

Stock intercooler shroud

The stock setup features a large center scoop that directs airflow through the intercooler core. This rubber unit flexes to seal against the intercooler. Next, we removed the hood insulation, destroying several

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

We've shared a ton of teasers that show our awesome charge-pipe design for the 2015 WRX. Now it is time to show you how this component came to life.

First, take a look at the factory-equipped charge pipe.

Stock 15' WRX charge pipe

Stock 15' WRX charge pipe

The stock pipe is a plastic unit that routes air from the front-mounted turbocharger to the hot side of the top-mount intercooler. The connection point with the turbocharger is a two-bolt flange. The intercooler connection is a simple coupler. This unit is similar to that featured on the Forester XT, and it is prone to boost leaks and clamp issues.

Our team then pulled off the piping and placed it on our CMM table to collect the dimensional data we would need to design our pipe.

Collecting dimensional data from stock 15' WRX charge pipe

Once

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

Size Comparison

Before installing our prototype cooler on one of our 2015 WRXs, we decided to take a few shots showing the huge size difference of our cooler compared to the stock unit.

Mishimoto prototype intercooler (left) and stock intercooler (right)

Mishimoto prototype intercooler (front) and stock intercooler (rear)

And a couple shots that better show the massive increase in core thickness.

Mishimoto prototype intercooler (left) and stock intercooler (right)

Mishimoto prototype intercooler (left) and stock intercooler (right)

Now it was time to install this cooler into a vehicle and ensure that fitment was spot-on. Check out a few shots.

Mishimoto prototype intercooler installed

Mishimoto prototype intercooler installed

Mishimoto prototype intercooler installed

Mishimoto prototype intercooler

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

3D Modeling

Now that the stock intercooler has been evaluated and modeled, we began designing our own cooler. Check out some of the initial models we put together for this prototype!

Stock (left) and Mishimoto prototype (right) intercooler model

Stock (top) and Mishimoto prototype (bottom) intercooler model

After testing this unit with CFD software to evaluate flow, we then worked up a few prototypes to check fitment.

Prototype Design Test Fit

To speed up our processes, we utilize a 3D printer to provide our engineers with actual components they can install on a vehicle to verify fitment. This means we can make changes before working up a real prototype, thus cutting down on the time needed to bring our cooler to market. So, we printed our end tanks in plastic, and then we attached them to

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

Many of you checked out our recent thread about our progress on the 2015 WRX top-mount intercooler. We are finishing some testing to ensure that our product will provide the improvements our customers expect. Our prototypes look awesome, and so far they are proving to be quite efficient. So, we've decided to back-track a bit and highlight the process our team went through to create such an awesome product. We will also be including our final test results, as well as information about how you can get your hands on one of the first units to hit the shelves. Keep an eye on our threads and blog; we have some exciting stuff in the pipeline!

How It All Started

In late March our team ventured nearly 250 miles to pick up our new 2015 CVT WRX. Shortly after, we launched a video review series, and our