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  1. Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 4: Initial Prototype Testing

    Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 4: Initial Prototype Testing

    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.

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  2. Stiffen Your 'Stang! 2015 Mustang Strut Tower Brace R&D, Part 5: Final Testing Rig and Results

    Stiffen Your 'Stang! 2015 Mustang Strut Tower Brace R&D, Part 5: Final Testing Rig and Results

    What a unique and exciting project this has been! We don't want to simply develop neat products; we want to understand how and why they function. This is why our team has been working to develop test protocols for our S550 Mustang strut tower brace evaluations. This segment shows our final testing process and the very surprising results.

    Final Testing Rig

    After experimenting with a setup designed to record pressure, we noticed that measuring travel distance between the two strut towers would provide identical results if we used a much more adaptable testing device.

    Our team acquired a few linear-displacement gauges to modify our strut brace for testing. We started by hacking apart one of our prototype bars.

    2015 Mustang parts testing
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  3. Treat Your Transmission. 6.0L Powerstroke Transmission Cooler R&D, Part 1: Factory Cooler Options

    Treat Your Transmission. 6.0L Powerstroke Transmission Cooler R&D, Part 1: Factory Cooler Options

    Yes, that's right, we are not quite done with product development for the 6.0L Powerstroke. Although these trucks are getting older, our team is finding more and more ways to enhance and improve them.

    The factory-equipped 6.0 transmission cooler is relatively stout. In fact, swapping this cooler into the 7.3L is a pretty common upgrade. That said, we think we can provide even greater cooling efficiency and offer an upgrade for 6.0L and 7.3L trucks that tow heavy loads.

    Factory Cooler Options

    From 2003­ to 2007, the 6.0L came from the factory with two different cooler options, a 26-row cooler and a 31-row cooler. Mounting and line connections were similar on both.

    Our shop truck came equipped with the 26-row unit, so we ordered the 31-unit cooler as well for data collection.

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  4. A More Durable Degas. Mishimoto's Ford Powerstroke 6.0L Aluminum Degas Bottle R&D, Part 2: Initial 3D Models

    A More Durable Degas. Mishimoto's Ford Powerstroke 6.0L Aluminum Degas Bottle R&D, Part 2: Initial 3D Models

    Quick update for this awesome degas bottle project! Our engineering team has been working to construct an aluminum degas bottle design for the 6.0, using our 3D-modeling software. We've incorporated some neat features, and we've included factory-style hose connection points and bottle mounts.

    Let's take a look!

    Mishimoto 6.0 Powerstroke degas bottle 3D model
    Mishimoto 6.0 Powerstroke degas bottle 3D model

    In this model you can see our plans for maintaining an appropriate fluid level. A simple sight tube will do the trick for our bottle design. You can also see the machined cap threads that we designed to function with the factory cap.

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  5. Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype

    Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype

    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
    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

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  6. Pipe Down! Mishimoto Fiesta ST Charge Pipe R&D, Part 5: Prototype Testing

    Pipe Down! Mishimoto Fiesta ST Charge Pipe R&D, Part 5: Prototype Testing

    We are nearing the completion of this project. Our engineering team is ready for dyno testing that will verify any power gains made with our larger-diameter intercooler piping. Exactly how much larger is the piping we designed?


    Fiesta ST charge pipe volume comparison hot side

    The Mishimoto hot-side design provided the greater increase in volume between the two, coming in at a 51% increase over the stock pipe.

    Fiesta ST charge pipe volume comparison, cold side
    Fiesta ST charge pipe
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  7. Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 3: Completed Prototypes

    Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 3: Completed Prototypes

    We're back with another update! Our team has been busy constructing our functional Ford Fiesta ST (FIST) intercooler prototypes, putting a lot of work into the R&D design stages, and now we get to see if it pay off. Enough of the wait, lets jump right into some images of our five prototype coolers.

    Ford Fiesta ST intercooler prototypes
    Ford Fiesta ST intercooler prototypes

    Ford Fiesta ST intercooler prototypes
    Ford Fiesta ST intercooler prototypes

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  8. Let Your Ponies Be Heard - Exhaust Components R&D, Part 1: Stock Evaluation

    Let Your Ponies Be Heard - Exhaust Components R&D, Part 1: Stock Evaluation

    At Mishimoto, our job is to bring you more than just exceptional cooling products. Another product category that we offer is exhausts, and what better car for an exhaust project than the fantastic-sounding Mustang GT!

    The stock system on the Mustang GT sounds pretty darn good as is, but after inspection we found some ways that we could improve on the stock design. If you aren't familiar, here are some photos of the stock Mustang GT exhaust.

    Stock Mustang GT exhaust Stock Mustang GT exhaust

    Stock Mustang GT exhaust Stock Mustang GT exhaust
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  9. Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 2: Initial Design Work

    Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 2: Initial Design Work

    After taking a brief look at the factory cooler and components, we needed to begin the design for our counterpart. This will involve the use of both modern and conventional tools to ensure that our prototype meets all our requirements.

    Factory Intercooler Features

    Factory F150 intercooler
    Factory F150 intercooler

    The factory intercooler pulled from our test vehicle came with the upper shroud that Ford had added to help prevent condensation issues. It also included a couple mounting pegs which use grommets for isolation.

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  10. Stiffen Your 'Stang! 2015 Mustang Strut Tower Brace R&D, Part 4: Testing Rig Fabrication Continued

    Stiffen Your 'Stang! 2015 Mustang Strut Tower Brace R&D, Part 4: Testing Rig Fabrication Continued

    Last time we wrapped up our first attempt at creating an accurate gauge for measuring strut tower flex. Our initial tests showed some inconsistencies, which have been attributed to the method by which we mounted our gauge.

    These inconsistencies occurred most likely because of the difference in materials. Our strut bar is steel, whereas the gauge assembly is aluminum. Welding these materials together is not possible, so we used alternate methods.

    We need to eliminate any adverse variables for this test. Measurements of movement are small, so even a seemingly insignificant issue could cause skewed data. We decided to work up a full aluminum prototype modeled after our first design.

    All-Aluminum Strut Bar Testing Prototype

    In addition to new machining tools, we have a new high-pressure Waterjet cutter here at Mishimoto. We decided to flex its muscles a bit and use it to cut out our strut bar brackets. These were then welded to the bar itself

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