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.
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 ModelsWe intend to offer this cooler in both a silver and black powdercoat finish, so we will show you a few render images of each. First, a look at the rear of the cooler. Continue Reading ››
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 others. Let’s dive right in!
F-150 Intercooler Shrouding FabricationThe footprint of our intercooler core is far larger than that of the stock intercooler. Because of this, it is likely that the airflow supplied by the stock bumper duct is not reaching the … Continue Reading ››
When we last had our test vehicle in the shop, the team fully evaluated the stock intercooler and piping system. In addition, we started to determine our projected core size and mocked up a foam prototype. In this segment, we will be expanding upon that by creating a mock-up prototype to test fitment.
3D-Printing PrototypeUsing our mock-up foam core dimensions and data from the factory intercooler, our team began to construct the end tanks using 3D-modeling software. To confirm fitment, each section was 3D printed to create a prototype that could be placed in the vehicle. This process required some trial and … Continue Reading ››
After taking a brief look at the factory cooler and components, we needed to begin the design for our counterpart. This will involve the use of both modern and conventional tools to ensure that our prototype meets all our requirements.