Intercooler 2015+ 2015

We're back with another quick update on our TGV delete project for the 2015+ WRX. After designing our initial models and then 3D-printing a prototype for test fitting, we worked up a couple functional prototypes for on-car testing.

First Prototype Images

Check out a few images of our functional prototype deletes!

Mishimoto's 2015 WRX TGV delete prototypes

Mishimoto's 2015 WRX TGV delete prototypes

As you can see, we have two different prototypes. Although the shape and design are the same, these prototypes are composed of different materials. The polished unit is a CNC-machined aluminum piece. The black prototype is machined from Delrin, a thermoplastic material.

We want to explore any differences in intake temperatures provided by the alternate materials. As you can imagine, thermoplastic has very low thermal conduction properties, meaning it is less likely to heat-soak and is more resistant to heat transfer. That said, the surface area that actually comes into contact with the internal

3D-Printed Prototypes

To confirm the dimensions and design of our prototype, we decided to utilize some of our rapid prototyping tools. We fired up our 3D printer and loaded the model. Check out a couple images showing the progress of the print.

3D-printing 2015 WRX parts

3D-printing 2015 WRX parts

Once the printing process was complete, we cleaned up the prototypes and installed them on our 2015 WRX to verify fitment.

3D-printed 2015 WRX parts

3D-printed 2015 WRX TGV delete installed

You will notice these prototypes include a rear flange to attach to the TGV solenoid. We experimented with a design that retains the flange, in order to bolt the stock solenoids in place for visual inspection purposes. After evaluating this setup, we decided the flange was unnecessary and removed it from the design. Our two functional prototypes will be more similar to our original 3D models.

Coming up - Functional Prototypes

With fitment confirmed, we began working up a couple functional prototypes for product

It's been nearly two years since our first 2015 WRX development vehicle rolled into the shop. We've had a lot of fun with the car, and our team has developed a multitude of awesome components to aid in cooling, elevate power, and improve styling. Our product line is essentially complete, meaning we are done wrenching on our WRX. This is bitter sweet, as we will be picking up another vehicle to start the process once again. Before shipping out the WRX, we had one more project up our sleeves to extract a touch more power.

With our existing modifications, including our downpipe, intake, and cat-back exhaust system, most customers are making in the neighborhood of 290 whp and 310 wtq. Not bad for some simple bolt-on modifications and ECU tuning. We've been eyeing TGV modifications and have seen the impressive effects on Subarus from previous model years. We decided to open up the intake system on our 2015 to see if we could design a delete system that would deliver a few extra ponies.

Stock

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