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Time for another update on our intercooler project! Last time we left off with a foam intercooler core and some cool 3D-printed end tanks. This update is a bit more exciting!

Mock Up Prototype

With both the tanks printed and our core cut to shape, we could mate these pieces to check fitment of our existing design.

Prototype Ford Fiesta ST intercooler assembled

The tanks feature the mounting pegs and brackets to attach the cooler to the radiator and support.

Interested in picking up our NB Miata oil cooler kit? Check out our discounted pre-sale linked below.

Mishimoto 1999-2005 Mazda Miata Oil Cooler Kit Pre-Sale!

During the previous articles we mentioned that we would be conducting experiments for the stock oil cooler/warmer. Myths and claims exist regarding its impact on the heating of engine oil as well as its impact on cooling. We decided to check out both sides of the spectrum and support them with some actual data. First up, warm-up speed both with and without the stock heat exchanger.

Testing Setup

Setting up the sensors and equipment for this test was relatively simple. For testing the system with the stock heat exchanger in place, we simply installed our oil sensor adapter below the filter and then installed our temperature sensor. Below is a look at the sensor adapter.

In our last post we took a look at the stock Fiesta ST downpipe as well as our slotted flange design based on the stock flange. We are still planning to create both a catted downpipe and a non-catted downpipe for race applications, so let's take a look at the progress!

Downpipe Design

After fitting the flange to the turbo, we began to piece together the rest of the downpipe coming off the flange and meeting with the exhaust. Both our designs feature a slotted flange that bolts to the turbo, in addition to a flex pipe near where they meet with the exhaust. This is important because the entire exhaust system will move a bit, and we need a flex point to allow for this. Not allowing room for flex in the downpipe would most certainly harm your exhaust system and possibly the turbo itself.
We began by laying out the components of our prototype next to the stock Fiesta ST downpipe for comparison. Check out some shots below!

Our engineering team often tackles complex problems to provide ideal solutions for customers. This is true for all our product lines, across a broad range of vehicle makes and models. We are not strangers to Ford's lineup of EcoBoost models, and our team is quite familiar with the issues that exist for each. In general, we've found that the stock liquid cooling systems are not handling the abuse from heavy-footed ST (Fiesta, Focus) and Mustang owners. Each model shows deficiencies in coolant heat transfer, rising oil temperatures, and power-crippling heat-soak.

In our effort to solve each problem, we've started a ton of awesome projects, performed unique testing, and we've had a blast working with the EcoBoost community. Now, we turn our attention to the Focus ST radiator. This component has become the elephant in the room, if the room were the paddock at the track. All around the world, Focus owners are hitting the track expecting a fun day of battles against physics, rev-match downshifts,

Time to dive into yet another Fiesta ST project! This little Fiesta is getting the royal treatment at Mishimoto; over the last few months it has been fitted for numerous upgrades. If you are in the mood for a recap, you can check out some of the other Fiesta posts here on the Mishimoto blog. For now we'll dive right into our development of Mishimoto's expansion tank for the Fiesta ST.

Stock Expansion Tank

Here at Mishimoto we feel a certain type of way about plastic. It is not that we have a vendetta against plastic, but we see an area where we can improve upon some of the stock Fiesta ST parts. Plastic expansion tanks in general (or any plastic parts) are more prone to failure than an aluminum part would be. Plastic becomes brittle with age, exposure to elements, and the repeated heat cycles in the engine bay. Replacing the plastic tank with an aluminum one not only looks better, but it also would be less prone to bursting or cracking especially as the

We've discussed R&D for many of our typical product segments for the Fiesta ST. These include our in-progress aluminum radiator, our already released catch can kit and oil cooler solution, as well as our nearly complete intake system and exhaust components (both cat-back and downpipe). Our company is also known for its strong line of heat exchangers, so we certainly need to see what can be done about the undersized stock intercooler on the Fiesta.

Heat is a big enemy of the Fiesta, as many have already discovered during track driving. High oil temperatures, high coolant temperatures, and a heat-soaked intercooler all commonly occur after short periods of aggressive driving. We've been actively tackling both the coolant and oil temperature concerns in other development threads, but now it's time to lower the intake temperatures with an upgraded intercooler.

Stock Intercooler Evaluation

You've probably seen the stock Ford Fiesta ST intercooler on

Interested in purchasing our E46 silicone radiator hose kit? Check out our product page linked below!

Mishimoto BMW E46 Non-M Silicone Radiator Hose Kit!

The E46 BMW has been the focus for a ton of product development here at Mishimoto. Recent projects include the Mishimoto Performance Air Intake, Aluminum Radiator, and Aluminum Expansion Tank. To continue our pursuit of supplying a full cooling solution for the 3-series, we also tackled a set of radiator hoses for this model. In typical Mishimoto fashion, we will be looking to improve the durability of the stock design.

Stock Hose Setup

The stock BMW E46 radiator hose system is unique, mostly due to the inclusion of quick-disconnect fittings at each mating point. Take a look at the stock hoses pulled from our test vehicle during radiator testing and development.

In our last post we took a good look at the stock Fiesta ST exhaust and the initial design of our cat-back exhaust. The exhaust was fabricated and installed on the car and then it was time to test the stock system.

To Resonate or Not to Resonate

Getting the sound just right was quite a process. Our initial prototype featured 2.5" piping with a single rear muffler. This design did not feature a resonated mid-pipe unlike the stock unit. The initial design was sound tested on the dyno and also test driven by several members of the team. While we loved the low growl of the exhaust as it was, we wanted to test a resonated version before settling on a final design. As with all exhaust development projects, we are aiming for a final product that sounds great on throttle while still being

Interested in picking up our NB Miata oil cooler kit? Check out our discounted pre-sale linked below.

Mishimoto 1999-2005 Mazda Miata Oil Cooler Kit Pre-Sale!

In our last segment, we outlined the goals of the project, and we started fabricating mounting brackets to position our heat exchanger under the front of the Miata NB (second generation). We also hinted at the use of shrouding to direct airflow properly through our cooler.

Optimal airflow through a heat exchanger is vital to the efficiency derived from an oil cooler system. In addition, we see value in retaining the stock engine undertray, which aids in the proper regulation of coolant temperatures. We will build our air duct into the undertray, with the goal of a stock-like appearance on the top of our list, right next to optimal airflow.

Air Duct Fabrication

First, we needed to create some space to fit our ducting. We ordered