Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!
Now that the stock intercooler has been evaluated and modeled, we began designing our own cooler. Check out some of the initial models we put together for this prototype!
After testing this unit with CFD software to evaluate flow, we then worked up a few prototypes to check fitment.
Prototype Design Test Fit
To speed up our processes, we utilize a 3D printer to provide our engineers with actual components they can install on a vehicle to verify fitment. This means we can make changes before working up a real prototype, thus cutting down on the time needed to bring our cooler to market. So, we printed our end tanks in plastic, and then we attached them to a 4” thick foam core. Yes, our cooler will have a 4” core! Check out a few shots of the process.
Once assembled, we put this unit on one of our vehicles to check a variety of clearances.
Once a few minor adjustments were made, we started the process of acquiring a real-world prototype. Check out our two units that will serve as the test subjects for this project.
Not only are these coolers powder coated different colors, but we have also designed two different cores for testing. The primary difference between the two is the intercooler bar height. The silver core features a slightly taller bar (around 2mm taller). After evaluating both of these core designs in terms of flow and heat transfer, we wanted to perform some real-world testing to see which actually performed better. Check out a few more detailed shots of these intercoolers.
First, a close-up of the core style we are using.
And a look at the cast end tank featuring our logo and port location for a gauge or meth injection.
That’s it for this installment. Check back next time for installed shots of this cooler, and a comparison of our cooler to the stock unit!
Thanks for reading.