6.7

We are back with a much-needed update on our 13+ Dodge Cummins intercooler. For most of our projects, we work with a donor vehicle to conduct fitment and performance testing. Unfortunately, this also means being patient when donor vehicles are not available for us to use. The good news is that we will not have to be patient for much longer, because testing is on our schedule! Once we complete testing in the coming weeks, we will be sure to share the results with you. In the meantime we can take a quick look at our finalized prototypes for testing!

Prototype Cummins intercooler and shroud

In our last post about the Cummins intercooler, we created a foam prototype with 3D-printed end tanks and cut a shroud on our waterjet. With our initial prototypes complete and fitment confirmed, we can move on to creating our final prototype for testing. That means handing the design over to our resident drafter and render wizard, Josh. He created some awesome renderings of what the final intercooler

Interested in purchasing this Cummins Intercooler? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Intercooler

Finally, the results are in! The testing of our 2010-2012 Cummins Performance Intercooler is complete. After months of development and weeks of testing, our team was extremely excited to crunch the numbers to see how our cooler compared to the stock unit. Before we jump into the actual data pulled from our dyno pulls, we will first compare the physical attributes of the Mishimoto cooler to the stock unit.

Intercooler Physical Comparison

First, our comparison of overall thicknesses of the stock and Mishimoto cores. This difference was displayed in an earlier post where we showed the actual measurements.

Stock vs Mishimoto intercooler core thickness comparison

As seen in the chart above, we are doubling the thickness of the factory cooler. Due to the design and placement of the intercooler, AC condenser, and radiator, we were able to expand this unit

Interested in purchasing this Cummins radiator? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Aluminum Radiator

Alright, it is finally time to see how our engineering team did with the development of this product! First, we measured the physical properties of the Mishimoto radiator compared to the factory radiator. Our first chart highlights the most common selling feature of a performance radiator: core thickness.

Mishimoto vs. factory radiator core thickness

We squeezed out as much additional core thickness as possible without causing any fitment concerns with factory equipment. The factory core came in at just under 1.7" thick, while the Mishimoto radiator measures 1.95" thick, making the Mishimoto radiator 13% thicker than the factory radiator. This additional core thickness allows our product to provide a greater fluid capacity and promote improved efficiency, which is reflected in the following charts. Our second chart shows the improvements made in

Interested in purchasing this Cummins Intercooler? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Intercooler

Time to see how efficient our cooler design is! We would be pulling our test truck onto our Dynojet to collect the data needed to evaluate the intercooler fully. Check out the conditions of our testing procedure below!

Testing Conditions

Vehicle: 2010 Dodge Ram 6.7L Cummins, Automatic Transmission, Performance Air Intake, Exhaust Modifications, Tune

Ambient Temperature: 70°F-76°F

Sensors: PLX Devices with Temperature sensors on both the intercooler inlet and outlet

Process: 6th^-gear pulls from 1,800 rpm to 3,200 rpm, with 4-minute breaks between each pull

Variable: Intercoolers were swapped on the dyno to ensure conditions were identical between the pulls.

Check out a few shots of this truck on the dyno!

6.7L Cummins test truck on dyno

6.7L Cummins test truck on dyno

The wiring harness you see coming from the engine bay connects to our temperature

Interested in purchasing this Cummins radiator? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Aluminum Radiator

Time to install our prototype radiator into a test vehicle to make sure that it fits perfectly. Luckily, we were able to check fitment on the same donor vehicle we used for our last round of testing. Once the truck rolled into the shop, we quickly installed our prototype radiator shown at the end of our last post. Check out a few shots taken during the installation process!

Mishimoto 6.7L Cummins radiator prototype installed

Mishimoto 6.7L Cummins radiator prototype installed

Mishimoto 6.7L Cummins radiator prototype installed

Mishimoto 6.7L Cummins radiator prototype installed

Once we confirmed that the primary radiator mounting points fit perfectly, we installed the shrouding for the top of the radiator as well as the mechanical fan and shroud. As with any test fit, we checked critical clearances to ensure that hoses and electrical components

Interested in purchasing this Cummins Intercooler? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Intercooler

Our prototype intercooler is ready to go! Let's take a quick peek at what our engineers designed!

Mishimoto 6.7L Cummins intercooler prototype

Mishimoto 6.7L Cummins intercooler prototype

First impressions, this cooler is massive compared to the factory unit. Our engineers weren't kidding when they mentioned that the size increase would be significant. You will notice two dimples on the intercooler outlet. They are predefined spots for injection systems such as methanol, or for a temperature/boost pressure sensor. These bungs are not predrilled, but they provide extra material thickness for those who wish to drill and tap the port. Pretty slick! You can also see from these images that our core is a solid bar-and-plate design. Now, let's compare the core thickness of the factory intercooler to the Mishimoto unit.

Factory 6.7L Cummins intercooler thickness

Interested in purchasing this Cummins radiator? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Aluminum Radiator

Now that we had our project objectives outlined, we could bring in a vehicle to begin the first stage of product development. After checking with our local contacts, we were able to locate the 2010 6.7L you see below!

2010 6.7L Cummins test vehicle

A big thank you to the owner of this truck! Take a look under the hood. This truck was equipped with some basic bolt-on modifications.

2010 6.7L Cummins test vehicle engine bay

2010 6.7L Cummins test vehicle engine bay

Once the truck was in our shop, we set to work removing the factory radiator. Our goal was to capture all critical dimensions on the radiator so we could use these data points to design our radiator. Additionally, we would be taking measurements on the vehicle to ensure any enlargements we made would not interfere with components on the truck. Check out a few images of the factory radiator

Interested in purchasing this Cummins Intercooler? Check out our product page for more information!

Mishimoto Dodge 6.7L Cummins Intercooler

Time to design an intercooler! Our first step toward this goal was to remove the intercooler so we could collect all the data points we needed. All front-end components were then removed from the truck to provide access.

Factory 6.7L components removed

Factory 6.7L empty core support

Take a look at the factory cooler tanks, mounting brackets and core!

Factory 6.7L Cummins intercooler

Once we had the factory intercooler out of the truck, we set it up on our CMM table to grab all the dimensions we needed. Using our Romer  arm, we can collect critical points in a controlled environment and use them in Solidworks to develop a prototype. Check out a shot of this intercooler being modeled!

Factory intercooler data collection

Once we collected all our points on both the intercooler and the body of the vehicle, our engineering team set to work designing