Tag Archives: ford

Everyday Hercules – Aluminum Radiator R&D, Part 1: Stock Review

Like the Roman hero Hercules, the 2015+ F-150 is capable of other-worldly feats. From the street to the jobsite, and even the dunes or the track, there’s little that the F-150 can’t conquer. With three available engines producing over 350 lb. ft. of torque, the 2015+ F-150 could probably stop the rotation of the earth. Even with all that power, many of the F-150’s on the road will never see Moab or drag a 1,000 lb. log up a mountain. But that doesn’t mean your F-150 shouldn’t be your everyday Hercules.

Owning an F-150 … Continue Reading ››

Diff’s Hot, Take it Easy – Rear Differential Cooler R&D, Part 4: A Tale of Two Track Days Part 1

The term “track day” around here is always surrounded with a certain level of enthusiasm. We’re all aware of the extra labor that goes into a trip to Raceway Park in Englishtown, NJ, but everyone involved is more than willing to pitch in for the chance to see our RS thrashed around the track. Think of it like one of those field trips you would take in middle school. Sure, there would be a test on everything seen that day, but that was a small price to pay for a day out of the classroom. After spending almost a week … Continue Reading ››

Old Dog, New Tricks – Intercooler R&D, Part 2: Plans & Prototypes

Tucked between the battery and the radiator, buried beneath a tangle of coolant hoses, lies the heart of the Ford Powerstroke 6.7L charge air cooling system.  This chunk of aluminum, the air-to-water intercooler, is responsible for keeping your workhorse breathing easy.

A freshly cut, $500 intercooler. Not a bad Tuesday
A freshly cut, $500 intercooler. Not a bad Tuesday

When we looked at this project last, we outlined what makes air-to-water intercoolers different from your typical air-to-air intercooler and why they’re used in heavy-duty applications.  We also took our waterjet … Continue Reading ››

Completing the Package – Intercooler Piping R&D: Coming in Hot

Fresh off the assembly line comes our prototype intercooler pipes for the 2013+ Ford Focus ST. In the last update, I reviewed the stock piping, our 3D printed prototypes, and mildly teased what the final version of this kit will look like, so it’s time for a full reveal. Let’s go through some of the design features and performance numbers that have resulted from this project.

Hot side intercooler pipes
Hot-side intercooler pipes

The hot-side kit will have a solid aluminum center section with silicone couplers attached to the turbo and intercooler … Continue Reading ››

Bye-Bye Blow-By – Catch Can R&D, Part 3: We All Love A Comeback Story

Who doesn’t love a good comeback? Rocky, Hoosiers, Robert Downey Jr., and Lindsey Lohan (kind of) are all prime examples of what makes the comeback story so compelling. The theme behind any good comeback is perseverance – not giving in to the will to stop.

Unrelenting perseverance will lead to beating seemingly impossible odds. It’s what led the 2005 Liverpool soccer team to beat the heavily favored AC Milan squad in penalties, and the 1993 Buffalo Bills to defeat the Houston Oilers from 32 points down, overcoming the largest point deficit in the NFL to date. Without perseverance, you won’t go … Continue Reading ››