All posts by John Marsteller

Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 7: Cold-Side Pipe Fabrication

Having already obtained precise dimensions from the factory piping and our test vehicle, our engineering team has begun the arduous, but rewarding process of developing and fabricating intercooler piping for our '11-14 F-150.

Cold-Side Intercooler Pipe Fabrication

Fabricating the cold side appears to be less of a challenge than dealing with the hot side, so we decided to … Continue Reading ››

Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 6: Pipe Fabrication

Along with creating an awesome intercooler for the EcoBoost (EB), we also want to improve upon the pathways through which air travels to and from the charge air cooler. This will involve replacing factory components that route from the turbocharger to the intercooler and from the intercooler to the throttle body with engineered aluminum pieces.

Factory Ford F-150 EcoBoost Intercooler Piping

The … Continue Reading ››

A Cooler Cummins. 2013+ Ram Intercooler R&D, Part 3: Prototype Test Fit

With our first prototype intercooler and shroud assembly complete, it was time to test fit and make necessary changes or adjustments.

Prototype Cummins Intercooler Test Fit

Using the factory mounting brackets, we bolted our components into place.
Proto Mock 1- EDIT
Mishimoto 6.7 Cummins intercooler prototype installed
The front shroud fits nice and snug against … Continue Reading ››

Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 5: Intercooler 3D Models

Now that our first prototype design has been finalized in Solidworks, we can begin constructing our first functional prototype to test both performance and fitment. Let’s check out some of the final features of our awesome intercooler design, including the appearance, the updated bracketry, the piping, and our innovative solution to the condensation issue!

F-150 Intercooler 3D Models

We intend to offer this … Continue Reading ››

Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 4: Intercooler Ducting

In our last entry, we finished the 3D-printing process for our first prototype intercooler. Our team then started the tedious work of modeling all the features we plan to implement and finalizing the details of our intercooler design. During this process, a new idea emerged that would both improve the performance of our cooler and set our kit apart from … Continue Reading ››