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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 ST performance parts

These dyno runs included two prototype cores, which were compared to the stock intercooler. Although both cores are of the bar-and-plate style, we intend to use this data to finalize our tube-and-fin intercooler. We saw higher pressure drops with our previous round of testing, so with this testing, we hope to determine the optimal core density that will provide an ideal compromise between pressure drop and heat transfer.

Pressure Drop Data

First, let's take a look at the pressure drop numbers from each of

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 cores to determine our final

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.

To collect temperature and pressure data, we installed two sensor bungs in each intercooler

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

Ford Fiesta ST intercooler prototypes

You might need a few seconds to let your heart rate recover!

We have quite a bit going on in these images. As you can see, there are three different color options. Each finish is powder-coated, and we intend to offer black, silver, and gold coolers for those looking to add some bold styling.

In addition to the various colors, we have three different cores among these five prototypes: one tube-and-fin core and two different bar-and-plate cores. Our goal here is to evaluate the differences in pressure, temperature, and power output between our prototype cores and the stock cooler. Take

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.

Prototype Ford Fiesta ST intercooler assembled

Prototype Ford Fiesta ST intercooler assembled

Once assembled, we installed this on our Fiesta to check fitment of the core and tanks. We want this piece to bolt into position like the stock cooler does, with no modification to the vehicle.

Prototype Fiesta ST performance parts

Prototype Fiesta ST performance parts

Prototype Fiesta ST performance parts

Fitment was pretty close on this first 3D printout. The core looks like it will fill the area quite well, thanks to the additional inch in

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 the forums or Internet when folks are replacing

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 and/or inefficiencies with the use of a top-mount intercooler setup.

Our first comparison point is internal flow area. This graph shows the volume of the actual air passages through the intercooler.

Comparison of internal flow area

Internal

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
• Mishimoto Front-Mount Intercooler
• Fuel Line Modification
• 3" Downpipe
• Tune

Check out a few shots of the car on the dyno!

Mishimoto GR STI on the dyno

Mishimoto GR STI on the dyno

As you can see, we have sensors installed on the piping, both the cold- and hot-side of the intercooler. We have pressure and temperature sensors hooked up

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!

Bugeye wagon with Mishimoto kit fully installed

This intercooler fills out the bumper completely and looks fantastic. Next up, a look at this kit fully installed on the Hawkeye.

Hawkeye with Mishimoto kit fully installed

And a couple shots of our finalized GR STi kit!

GR STi with Mishimoto kit fully installed

GR STi with Mishimoto kit fully installed

Now that we had all of our kits developed, the project is complete, right? Wrong! We haven't tested this intercooler out yet! Now, we have conducted a ton of CFD and core