Page 8 - ford

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

The testing of our Fiesta ST rear strut brace involved three different driving conditions.

Cornering: 30-40 mph, slalom

Braking: 50-0 mph, stop with ABS engaged

Acceleration: 0-60 mph, full-throttle run

Each setup (with and without brace) was tested on the same day on an identical surface and with the same driver. The tests are repeatable and will provide an accurate comparison of rigidity in the rear body portion of our Fiesta.

Results

Check out the plot below to see our testing results.

Fiesta ST performance results

These data points confirm our theory that the addition of bracing in this area of the ST does indeed have an impact on flex. Although flex in these conditions

When we last had our test vehicle in the shop, the team fully evaluated the stock intercooler and piping system. In addition, we started to determine our projected core size and mocked up a foam prototype. In this segment, we will be expanding upon that by creating a mock-up prototype to test fitment.

3D-Printing Prototype

Using our mock-up foam core dimensions and data from the factory intercooler, our team began to construct the end tanks using 3D-modeling software. To confirm fitment, each section was 3D printed to create a prototype that could be placed in the vehicle.

This process required some trial and error to ensure that the 3D model was as accurate as possible. The inlet/outlet portions were the most challenging, so these were printed and tested first.

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Now that we have designed our 6.0L transmission cooler prototype in SolidWorks®, our team has begun work on constructing our first prototype. We will be using this prototype to verify fitment on our truck and perform heat-soak testing to determine any cooling benefits provided by the larger core size.

Mishimoto 6.0L Transmission Cooler Prototype

Check out a couple shots of our first prototype unit!

Mishimoto 6.0 Powerstroke transmission cooler

With a rough 3D model in place, we started constructing our 3D-printed prototypes to finalize our 6.0L degas bottle design and to refine any areas where adjustments are needed.

Due to the large size of this degas unit, we printed the bottle in multiple sections and then attached each portion together.

Below is a look at our first 3D print fitted into place on our 6.0L.

3D-printed 6.0 Powerstroke degas bottle

3D-Printed 6.0 Powerstroke degas bottle

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

In our last update, we left you with some mock-up prototype pieces that we used to create and refine our Fiesta ST rear strut brace design. Since then, we've worked up a couple of functional prototypes to test our ideas for stiffening the rear of this hot hatch.

Initial Prototypes

We constructed two prototypes of this trunk brace. The first prototype is finished in a black powder coat, and we'll use this unit to evaluate for aesthetics and fitment. The unfinished ("raw") prototype is going to be used for testing purposes, meaning it will be modified.

First, check out our powder-coated unit bolted into place.

Mishimoto Fiesta ST performance parts