Page 5 - cooling

After evaluating the factory intercooler, our team was prepared to begin designing an intercooler with even more efficiency. The process started as a simple 3D model that included our primary mounting points. This model was then sent to the 3D printer for some rapid prototyping.

3D printing Cummins intercooler end tank

Once our tanks were complete, we mated the different pieces using adhesive.

3D printing 6.7 Cummins intercooler end tank

For those of you not familiar with the climate here in New Castle, Delaware, let me educate you on our summers; they are hot, and they are HUMID. In the dead of the July heatwave, there is nothing worse than smoldering in an apartment with no AC. I am always very appreciative of the little part of my psyche that drives me, once I can barely stand the heat, to pause Top Gear, get off the couch, and grab a cold, refreshing drink. If I were a car, that little part of my psyche would have a name, and it would be called a thermostat.

2016 Camaro thermostat housing (OEM) next to some of our other 2016 camaro parts

What is a Thermostat, and in what Neighborhood

We are narrowing down our selection of core designs through both extensive research and some pretty neat testing processes. After seeing some impressive heat transfer numbers on our first round of Ford Fiesta ST intercooler testing, we decided to focus on producing a better balance between pressure drop and reduction of intake temperatures.

New prototypes were constructed, and we were ready to make some dyno runs.

Testing Fiesta ST performance parts

Testing Fiesta

Mishimoto has been involved in the heat exchanger business for quite some time. Our team has produced many optimal aftermarket cooling solutions for vehicles new and old. We are finding now that OE heat exchangers have been improving substantially. This is occurring because vehicle curb weights have risen, and the horsepower war has continued to produce increasingly massive power output numbers.

Now, this isn't to say there isn't room for improvement. Stock cooling systems are typically adequate for a stock vehicle in street-driving conditions and in some instances, light track driving. Once owners begin adding sticky tires for longer-duration lapping, stock heat exchangers have trouble keeping fluid temperatures properly regulated.

Considering the weight and power output of the 2016 Camaro, we expect to see a need for improvement in both the primary and secondary radiator systems. This particular R&D project will cover the creation of our aluminum primary radiator for this vehicle.

With our final prototype in hand, our team went to work bolting everything into place. We've made minor tweaks to the design, so we just want to be sure fitment is spot-on for our final iteration.

Check out a few shots from the final install.

Ford Fiesta ST Intake fully installed

Ford Fiesta ST Intake fully installed

Everything bolted on perfectly, and this setup looks quite nice in the engine bay of the Fiesta. We will be making one small adjustment

Our quest for the perfect intercooler core continues! So far we've perfected the fitment and size of our intercooler core. Our final task is to adjust internal fin composition to create a perfect blend of pressure retention and temperature benefits.

Prototype Ford Fiesta ST Intercooler Fabrication

Timing is a bit of a concern for us at this time. This project has been lengthy, but it will be worth the effort and time when we know our best efforts have been captured in our final product.

Our final version of this intercooler will likely feature a tube-and-fin core. The benefits of weight and airflow are too important to ignore, not to mention the temperature drops we are seeing with a strategically designed internal core.

For our team, the creation of a bar-and-plate cooler is a much quicker process. We've found that pressure drop between the two core types is similar if fin style, density, or both are the same. So for this test, we are using two bar-and-plate

The most exciting part of product R&D is always the testing phase. This typically includes setting up some neat sensors, running the car on the dyno or on the street, and crunching our data. We are anxious to see how our first prototype coolers perform on the Fiesta. Let's jump right into the plans for this first round of testing.

Testing Plans

As mentioned in the previous segment, we will test four different coolers.

• Stock intercooler
• Mishimoto bar-and-plate prototype 1 (larger internal bar height)
• Mishimoto bar-and-plate prototype 2 (smaller internal bar height)
• Mishimoto tube-and-fin prototype

For each cooler we will be collecting data for temperature, pressure, and power output. Each cooler will be tested repeatedly until we have three consistent runs producing data as accurate as possible.

Below is a look at the three different core types that will be tested.

We are quite excited about the completion of our final prototype intake for the Ford Fiesta ST (FIST)! After months of development, testing, and design work, we are ready to present our final creation. First we will go through each component and cover important details regarding their features.

Silicone Turbo Inlet Hose

Starting at the turbocharger compressor inlet, we have our silicone inlet hose. This piece was constructed specifically for this kit and is extremely robust.

Mishimoto's Ford Fiesta ST intake silicone inlet hose

Five layers of silicone comprise this hose, along with embedded fibers and steel wire for added rigidity. This hose must withstand the suction created