Page 12 - turbo

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

It has been quite some time since our last update on this project, but for good reason. Our engineering team has immersed themselves into suspension research and determining the impact of stiffening on handling. Chassis bracing is a new market for our team, and we want to ensure we provide ideal solutions. In addition, we needed to develop a method for testing our components properly.

Not much information is available about the effectiveness of strut bracing. Would bracing have an impact on handling or on chassis flex? Do only sloppy, old chassis benefit from bracing? The Mustang is a great first test subject because it has a new chassis and an option for additional chassis stiffening. Let's get to work!

Pressure Gauge Fabrication

The first testing device we wanted to explore was a pressure gauge. Ideally, this would be installed within the strut brace to measure any pressure occurring as the strut towers flex toward each other.

With some

We've got some interesting plans to evaluate the performance benefits of our TGV delete kit. In addition, we want to evaluate any appreciable differences in terms of air temperature between the two materials (aluminum and Delrin) we have selected for our prototypes.

Test Preparation

For our first assessment, we will evaluate airflow temperatures in both materials during dyno testing. The goal here is to determine whether the different heat transfer properties of the two materials have an impact on the airflow within the TGV unit. Ideally we would use pre-TGV and post-TGV sensors to evaluate this, but for our initial test a single sensor will be used.

We started by drilling and tapping each prototype.

Initial Data

We put together several plots to help analyze the data from our dyno pulls so we could reach a conclusion regarding appreciable temperature differences. First, a look at our initial runs with each material on

In our last post for this project, we went through the stock system and left you with a teaser look at our initial design plans for the filter's heat shield. We now have a functional prototype fabricated, which will soon be ready for testing. Let's go through the interesting process of how we were able to make the heat shield and pipe.

Parts Fabrication

Usually, when it comes to creating the pieces to a heat shield, our process involved measuring twice and cutting once with the use of a band-saw, shears and a bender. It was laborious and time-consuming.

With this project, we took a slightly different approach during the design and prototyping phase of our heat shield R&D. After capturing the dimensions we needed from the vehicle, a prototype design was drawn in 3D modeling software. Once completed, we used our waterjet machine to cut the shapes out of the steel metal sheets.

If you don't know about the waterjet, it is an apparatus for

Great news from the Mishimoto garage! We have tested and fitted the final iteration of our airbox design for this prototype MK7 intake. We made some minor adjustments for fitment and ease of installation, but more on that later. This has been an interesting project from the start because of the uniqueness of this box design - check it out!

Final Intake System

Once this prototype system was ready to go, we prepared it for final fitting into the MK7. The next step is paint! The final products will be powder coated, with the intake pipe color options ranging from wrinkle black/red powdercoat or chrome polish. So the painted parts below are just for visualization purposes.

Prototype MK7 parts drying from paint