Low Road – 2021+ Ford Bronco 2.3L/2.7L Performance Stock Location Intercooler R&D, Part 2 – Prototyping

It’s no secret that the Bronco wasn’t resurrected to break land speed records. Just one look at this brick on towing off-roading tires makes it apparent that this machine was destined for more wild pathways. No matter where these Broncos feel at home, more power is still a necessity both on the trail and for the commute to work. Luckily, Ford stuffed different iterations of their platform that’s become synonymous with power potential – the EcoBoost. Whether it’s the 2.3L or the 2.7L, these engines have plenty of surplus performance locked away that can be accessed with the correct key. In this case, that key is intercooler shaped.

For that lock to turn and open the vault full of speedy treasures, it needs to be the right size and shape to align the tumblers perfectly. The story is the same when it comes to our Bronco intercooler design. Fitment is key. We put our scanning and sophisticated modeling software up to the task of creating a precise new design that fits in our digital workspace, but these can only take us so far. Without triple-checking our work, this fancy new core and perfectly sculpted end tanks end up being just a nice garage decoration. So, instead of waiting for the first round of production units to be ready, we created a fitment prototype. 

This is just a quick preview of our new design next to what Ford equipped on the Bronco from the factory. The thicker core is much better suited for tunes and other performance upgrades, or even just contending with extreme heat on less modified rigs.

Thanks to the teamwork of our master fabricator, Mike, and the bank of 3D printers, we can bring a 1-to-1 scale replica of our new intercooler to life in a matter of hours. Using this prototype, we can fit our design on the vehicle and account for any potential obstacles or variables we can’t fully replicate in the digital world. Adding this step also helps streamline our process since we can make any necessary adjustments to our design before even making production tools. 

With the key fit, we’re eager to see what’s locked inside the Bronco’s vault of performance potential. Make sure that you stay tuned for the first look at our production sample coming soon.

Thanks for Reading!

-Nick

Leave a Reply

Your email address will not be published.