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Now that our first prototype design has been finalized in Solidworks, we can begin constructing our first functional prototype to test both performance and fitment.

Let's check out some of the final features of our awesome intercooler design, including the appearance, the updated bracketry, the piping, and our innovative solution to the condensation issue!

F-150 Intercooler 3D Models

We intend to offer this cooler in both a silver and black powdercoat finish, so we will show you a few render images of each. First, a look at the rear of the cooler.

Mishimoto Ford F-150 EcoBoost intercooler prototype

Here we see the two inlets and single quick-disconnect outlet. We also

Improving airflow is now a recurring theme for the stock 2015+ Mustang GT intake. In addition to finding air flow restrictions in our project to replace the entire stock intake system, we've also found several ways that a silicone induction hose for S550 drivers could improve airflow for drivers who would rather not replace their stock intakes. The stock piece is not only restrictive in size, but it also makes use of a resonator. We can make several improvements to take this induction hose design to the next level.

Stock 2015+ Mustang parts

We've had our Mustang GT for a good while now, and it's time to begin our development of the performance intake. We'll begin by quickly dissecting the stock system and deciding on the direction we'd like to go with our design.

Stock 2015+ Mustang GT intake

The stock intake is fairly standard; from the center-mounted throttle body, the intake tube extends toward the driver side of the engine bay and incorporates the curved design that embodies the style of that classic V8 intake.

We are back with more on our Fiesta ST downpipe project. We know you are long overdue for an update, so we'll dive right in. After fabrication, we read that some other aftermarket downpipes for the Fiesta ST weren't as successful at making power as downpipes typically are on other applications. We still wanted to test our downpipe designs to see the data for ourselves, and decide if the downpipe was worth manufacturing for the Fiesta ST.

After testing was completed, the data confirmed our suspicions that the Fiesta ST is pretty darn efficient on its own, and the addition of a downpipe did not show any gains in power. Even still, we have decided to kick this into production for those who want the sound benefit, and for those who have more modified Fiesta STs.

A tune will be required to run this downpipe, and of course actual power gains will depend the tune itself and the supporting modifications to your ST.

In our last post we took a look at our plans for the Mustang radiator and how we were designing it in Solidworks. Thanks to the speedy design, our first functional prototype is complete and ready for some test fitment!

Straight out of the box, it is quite a hefty unit and should provide some much needed cooling for this GT. Check out some installed photos of our functional prototype.

Mustang radiator installed

Mustang radiator installed

In our last entry, we finished the 3D-printing process for our first prototype intercooler. Our team then started the tedious work of modeling all the features we plan to implement and finalizing the details of our intercooler design. During this process, a new idea emerged that would both improve the performance of our cooler and set our kit apart from others.

Let's dive right in!

F-150 Intercooler Shrouding Fabrication

The footprint of our intercooler core is far larger than that of the stock intercooler. Because of this, it is likely that the airflow supplied by the stock bumper duct is not reaching the entire surface area of our cooler. To combat any issues with loss of airflow, we decided to experiment with some ducting to direct air through the core.

We began the fabrication process with a few old-school techniques; our engineers broke out the template material and a measuring device and started cutting out some ideas.

It's now time to install our prototype and put some data behind the efficiency differences we expect to see between our cooler and the factory heat exchanger. We did add a substantial amount of core surface area, so we anticipate that heat transfer will improve during a load test. Check out this shot of the Mishimoto 6.0L transmission cooler installed!

Mishimoto 6.0 Powerstroke transmission cooler installed

Testing Process

We have numerous tools at our disposal to test heat exchangers. For this one, we will be using our Dynapack™ dynamometer. With a transmission cooler test, we want to apply some load on the vehicle to ensure that stress is created within the drivetrain. We