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We are narrowing down our selection of core designs through both extensive research and some pretty neat testing processes. After seeing some impressive heat transfer numbers on our first round of Ford Fiesta ST intercooler testing, we decided to focus on producing a better balance between pressure drop and reduction of intake temperatures.

New prototypes were constructed, and we were ready to make some dyno runs.

Testing Fiesta ST performance parts

Testing Fiesta

Our quest for the perfect intercooler core continues! So far we've perfected the fitment and size of our intercooler core. Our final task is to adjust internal fin composition to create a perfect blend of pressure retention and temperature benefits.

Prototype Ford Fiesta ST Intercooler Fabrication

Timing is a bit of a concern for us at this time. This project has been lengthy, but it will be worth the effort and time when we know our best efforts have been captured in our final product.

Our final version of this intercooler will likely feature a tube-and-fin core. The benefits of weight and airflow are too important to ignore, not to mention the temperature drops we are seeing with a strategically designed internal core.

For our team, the creation of a bar-and-plate cooler is a much quicker process. We've found that pressure drop between the two core types is similar if fin style, density, or both are the same. So for this test, we are using two bar-and-plate

The most exciting part of product R&D is always the testing phase. This typically includes setting up some neat sensors, running the car on the dyno or on the street, and crunching our data. We are anxious to see how our first prototype coolers perform on the Fiesta. Let's jump right into the plans for this first round of testing.

Testing Plans

As mentioned in the previous segment, we will test four different coolers.

• Stock intercooler
• Mishimoto bar-and-plate prototype 1 (larger internal bar height)
• Mishimoto bar-and-plate prototype 2 (smaller internal bar height)
• Mishimoto tube-and-fin prototype

For each cooler we will be collecting data for temperature, pressure, and power output. Each cooler will be tested repeatedly until we have three consistent runs producing data as accurate as possible.

Below is a look at the three different core types that will be tested.

We're back with another update! Our team has been busy constructing our functional Ford Fiesta ST (FIST) intercooler prototypes, putting a lot of work into the R&D design stages, and now we get to see if it pay off. Enough of the wait, lets jump right into some images of our five prototype coolers.

Ford Fiesta ST intercooler prototypes

Ford Fiesta ST intercooler prototypes

Time for another update on our intercooler project! Last time we left off with a foam intercooler core and some cool 3D-printed end tanks. This update is a bit more exciting!

Mock Up Prototype

With both the tanks printed and our core cut to shape, we could mate these pieces to check fitment of our existing design.

Prototype Ford Fiesta ST intercooler assembled

The tanks feature the mounting pegs and brackets to attach the cooler to the radiator and support.

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We've discussed R&D for many of our typical product segments for the Fiesta ST. These include our in-progress aluminum radiator, our already released catch can kit and oil cooler solution, as well as our nearly complete intake system and exhaust components (both cat-back and downpipe). Our company is also known for its strong line of heat exchangers, so we certainly need to see what can be done about the undersized stock intercooler on the Fiesta.

Heat is a big enemy of the Fiesta, as many have already discovered during track driving. High oil temperatures, high coolant temperatures, and a heat-soaked intercooler all commonly occur after short periods of aggressive driving. We've been actively tackling both the coolant and oil temperature concerns in other development threads, but now it's time to lower the intake temperatures with an upgraded intercooler.

Stock Intercooler Evaluation

You've probably seen the stock Ford Fiesta ST intercooler on

Interested in purchasing our Subaru WRX or STi intercooler kit? Check out more details on our product pages linked below!

Mishimoto Subaru WRX/STi Front-Mount Intercooler, 2001-2007

Mishimoto Subaru WRX Front-Mount Intercooler, 2008-2014

Mishimoto Subaru STi Front-Mount Intercooler, 2008-2014

Time to review our data so we can finally put a close on this project. The product development process for this front-mount intercooler has taken months and has also helped refine several of our processes. Before we move into the testing data, our first portion of this post will cover the physical benefits of our intercooler. By providing a more efficient heat exchanger, we can ensure that higher-powered vehicles are not being hindered by debilitating heat-soak

Interested in purchasing our Subaru WRX or STi intercooler kit? Check out more details on our product pages linked below!

Mishimoto Subaru WRX/STi Front-Mount Intercooler, 2001-2007

Mishimoto Subaru WRX Front-Mount Intercooler, 2008-2014

Mishimoto Subaru STi Front-Mount Intercooler, 2008-2014

We are nearing the end of this build. As mentioned in the last post, we wanted to put our core to the test and provide some cooling efficiency data that our customers could use. We decided to modify our 2010 STi to add some heat and power to the CAC system for testing. Information regarding our vehicle is listed below.

2010 Subaru WRX STI

• 6-Speed Manual
• Mishimoto Intake

Interested in purchasing our Subaru WRX or STi intercooler kit? Check out more details on our product pages linked below!

Mishimoto Subaru WRX/STi Front-Mount Intercooler, 2001-2007

Mishimoto Subaru WRX Front-Mount Intercooler, 2008-2014

Mishimoto Subaru STi Front-Mount Intercooler, 2008-2014

As promised, we have a couple cool images showing these kits fully installed on our test vehicles. Check them out below!

First, our full kit installed on our shop 2003 WRX Bugeye wagon!