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mkIII

  1. Completing the Package - Intercooler Piping R&D: Coming in Hot

    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 outlet. It fits nicely around the engine oil pan and is mounted with brackets to keep it in place. However, a balance between flexibility and rigidity is important, which is why the couplers are long.

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  2. Cooler Than Winterfell - Intercooler R&D, Part 3: Does It Perform?

    Cooler Than Winterfell - Intercooler R&D, Part 3: Does It Perform?

    We've noticed that the 2013+ Ford Focus ST has little wiggle room when it comes to gaining power strictly from bolt-on parts. Even with stage 3 tunes, not many ST's out there see horsepower numbers beyond 300-350hp. That barrier can be surpassed with the use of ethanol or a bigger turbo, but on a stock turbo and pump gas, those numbers aren't going too far north.

    With our intercooler, we wanted to bring on some positive effects for the power in this stubborn 2.0L engine. While power is important, we also needed to monitor the outlet temperatures with a visual analysis of heat transfer across the core.

    Setting up our prototype for some dyno runs
    Setting up our prototype for some dyno runs

    One of our newer pieces of equipment is a neat little

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  3. Cooler Than Winterfell - Intercooler R&D, Part 2: Prototype Core

    Cooler Than Winterfell - Intercooler R&D, Part 2: Prototype Core

    It looks like mother nature is giving the tell-tale signs to us gearheads that it's time to get ready for track season. The weather is getting warmer and tracks all around the country have kicked off calendar seasons with maiden 2017 events already in full swing. A common mod many of us who are boosted, especially ST owners, want during this time of year is the intercooler. The 2013+ Ford Focus ST features quality design for its the factory intercooler, but improved efficiency is something we like to target. In the last update, we talked about the shortcomings of the factory core and how we plan to make an even more efficient intercooler. Now that we have received our production samples for the first time, we can get into the details of the design plan and what our goals are to improve performance.

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  4. Tank Love - Expansion Tank R&D, Part 2: Final Reveal

    Tank Love - Expansion Tank R&D, Part 2: Final Reveal

    I told you this project was going to move fast. In the last update, we laid down our design plans for how we will give this RS coolant expansion tank some sprucing up. Not only did we make the tank more pleasing to look at, we also increased the capacity and added a neat sight tube so you can check your levels with ease. You guys have been asking for it, so let's get up close and personal.

    The stock unit pales in comparison to the size of the Mishimoto tank.
    The stock unit pales in comparison to the size of the Mishimoto tank.

    One of the first things you'll notice with this tank is the capacity increase over the stock unit. We are making this tank to fit both the Focus RS and ST, but that doesn't mean we have to stay within the size parameters

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  5. Tank Love - Coolant Expansion Tank R&D, Part 1: Design Plans

    Tank Love - Coolant Expansion Tank R&D, Part 1: Design Plans

    Anyone with a car older than 15 years or so likely has a coolant expansion tank with the structural integrity of wet toilet paper. These tanks rarely get aesthetic love in the factory vehicle design. They are usually plastic, look weird and can start cracking given enough time. After 20 years, the expansion tank in my 1995 Nissan 240SX project car will literally begin crumbling around your finger if any sort of pressure is applied. We don't want that happening to your RS/ST a decade or two from now, so we decided to design a sweet looking expansion tank that will outlast the car and be a nice addition to your engine bay.

    The stock cap is has a pressure limit of 21psi
    The stock cap on the RS has a pressure limit of 21psi

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  6. The Final Product - Focus ST Intake, Part 4

    The Final Product - Focus ST Intake, Part 4

    We have an update for our Focus ST intake project! Our first production sample has finally reached our R&D facility, and we have been able to test fit it onto a 2013 Ford Focus ST. Fitment was spot on, and we were able to get all the components properly snug into the car. We made some minor adjustments from our initial design and we included an awesome new feature that will help accommodate more Focus ST's on the road, so let's check it out!

    It's the Little Things

    During the time we were updating our design, we discovered small differences between the stock 2013"2015 and the 2016+ Focus ST intakes. The 2013"2015 Focus ST's have a screw type mass airflow (MAF) sensor that goes into the stock pipe. In the 2016+ model, however, the MAF sensor is replaced with an IAT sensor in the same location and it fits into a push-type clip housing. Many aftermarket intakes retain use of the stock accordion style boot that holds the sensor in place, " especially in

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