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Final Prototype Bracket
Welcome back! Our final bracket prototype is in and ready for installation. Check it out!
We mentioned in our 6.0L coolant filtration thread that we would be tackling the 6.4L as well. Let's take a look at some of the components our team has been putting together for the 6.4L kit.
Although the 6.4L does not seem to be as susceptible to buildups as is the 6.0L, a coolant filtration setup is certainly still a worthy investment in preventive maintenance.
So let's get started!
Filter Housing
We'll start with the filter housing. As mentioned in our 6.0L thread, we developed a housing with a wide range of adjustability that could be utilized for a variety of kits. This housing is shown below.
Our full prototype unit has arrived and is ready for some final test fitting! Before introducing our final product, let's take one last look at the stock hose setup.
Now, check out the Mishimoto prototype kit!
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The Project Begins
Looking to pair your 6.4L aluminum radiator with a nice set of silicone hoses? We thought so! After developing a variety of components for the 6.4L Powerstroke, we decided to take a closer look at the radiator hoses on this truck.
After Ford released this truck in 2008, there were numerous complaints about leaking hoses. Ford issued a technical
With our testing complete, it was time to recap the results and see what kind of benefits our cooler was capable of producing. The testing procedures and information from our previous posts are outlined below.
Testing Procedures and Information
Vehicle: 2011 Chevrolet 2500 6.6L LML Duramax
Engine Modifications: None, all factory equipped
Ambient Temperature: 85°F (29.5°C)
Humidity: 35%
Sensors: PLX Pressure and temperature sensors were placed on both the hot-side and cold-side intercooler boots.
Physical Benefits
Before we jump right into the testing data, let's compare the physical aspects of our intercooler design that distinguish our unit from the factory cooler.
Product Testing and Procedures
The fun part of development is the reveal of our initial prototype design, but the truly exciting part is the testing portion of development. At this point our offices are disrupted by noise from the dyno pulls, tempting a few of our empolyees to filter into the garage and check out the action. Below we see the truck loaded onto the dyno.
Finally, the results are in! The testing of our 2010-2012 Cummins Performance Intercooler is complete. After months of development and weeks of testing, our team was extremely excited to crunch the numbers to see how our cooler compared to the stock unit. Before we jump into the actual data pulled from our dyno pulls, we will first compare the physical attributes of the Mishimoto cooler to the stock unit.
Intercooler Physical Comparison
First, our comparison of overall thicknesses of the stock and Mishimoto cores. This difference was displayed in an earlier post where we showed the actual measurements.
Prototype Test Fitting
Time to see if this massive intercooler fits! Our prototype design was based on critical dimensions taken from a test vehicle so we could expand the cooler as much as possible without causing fitment concerns. Let's see if we succeeded on our first attempt!
The radiator and intercooler are thicker than the factory units, so we bolted the intercooler prototype to the new Mishimoto radiator prototype. Now attached to each other, we installed them together for the benefit of those customers who would want to purchase both components.
Prototype 3D Design
Now that we outlined our project goals and had all the test data from the factory intercooler, our engineers were ready to design a prototype intercooler. Using dimensional data from a rendering of the truck as well as the actual measurements we took from the test vehicle and factory intercooler, our team was able to create a very nice looking prototype. Check out a couple renderings of the design!
Alright, it is finally time to see how our engineering team did with the development of this product! First, we measured the physical properties of the Mishimoto radiator compared to the factory radiator. Our first chart highlights the most common selling feature of a performance radiator: core thickness.
We squeezed out as much additional core thickness as possible without causing any fitment concerns with factory
