Having already obtained precise dimensions from the factory piping and our test vehicle, our engineering team has begun the arduous, but rewarding process of developing and fabricating intercooler piping for our '11-14 F-150.
Cold-Side Intercooler Pipe Fabrication
Fabricating the cold side appears to be less of a challenge than dealing with the hot side, so we decided to start there to get the ball rolling. Following the path of the factory piping, we began fabrication at the intercooler side of the pipe and worked our way up toward the throttle body.
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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.
Factory Ford F-150 EcoBoost Intercooler Piping
The factory piping setup on the F-150 is essentially a rat’s nest of molded plastic and rubber couplers that, evident upon removal, is complemented by an internal coating of oil. No wonder catch cans are so popular for these trucks!
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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 Models
We 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.
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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 Fabrication
The 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.
Using 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 ››