Does the 2015 WRX Need an Upgraded Intercooler? Part 4: Charge Pipe Development
Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!
We've shared a ton of teasers that show our awesome charge-pipe design for the 2015 WRX. Now it is time to show you how this component came to life.
First, take a look at the factory-equipped charge pipe.
The stock pipe is a plastic unit that routes air from the front-mounted turbocharger to the hot side of the top-mount intercooler. The connection point with the turbocharger is a two-bolt flange. The intercooler connection is a simple coupler. This unit is similar to that featured on the Forester XT, and it is prone to boost leaks and clamp issues.
Our team then pulled off the piping and placed it on our CMM table to collect the dimensional data we would need to design our pipe.
Once we had the critical dimensions mapped out, the engineers began designing a charge pipe in Solidworks.
There are a few neat features about this particular design. First, the lower portion you see in this rendering is actually a cast aluminum unit. This enabled us to achieve the appropriate bends to clear all stock components in the area of this pipe. Additionally, we incorporated the stock two-bolt flange to mount directly to the turbocharger housing. Our pipe utilizes the stock port for the bypass valve (BPV) as well. Our overall design follows essentially the same path as the stock pipe. That being said, we have enlarged the internal volume of this pipe quite significantly.
Now that our 3D rendering was complete, we sent the file over to our 3D printer to get a plastic unit ready for test fitting.
This piece was then installed to confirm fitment!
Once complete, we worked up a few final prototypes. Check them out!
First, our polished example.
We also had a prototype powder coated wrinkle black. This one looks fantastic, very factory-like.
That last shot shows our cast logo on the base of the pipe as well as the O-ring being used on the pipe connection to the turbocharger. This O-ring will be included with the pipe.
These units were also installed on our 15' WRX to verify fitment. We are considering adding a wrinkle-red finish to the lineup. Let us know if this is something you guys would like to see.
Our final intercooler and charge-pipe testing data will be posted next. Watch for that next week!