Page 14 - Engineering

Innovation moves fast these days. Anything heralded as a technological feat is already outdated by the time it hits the market. Well, sort of. BMW has a knack for engineering iconic cars, specifically when it comes to the benchmark of the performance compact sedan: the M3. The launch of the G8X M3 and M4 might have delivered polarizing looks, but this generation's performance leaves a lasting impression. But even though it's the most powerful M of this class to date, enthusiasts still want more, and an upgraded air intake kit is the best starting point. 

The upside to fast-moving innovation is that it helps streamline our process. Once upon a time, our intake development took a long time. There was much more custom fabrication and manual measuring required to generate a prototype. Thanks to the wide array of tech housed under our R&D facility's roof, we're

In a world of drive-anywhere, tow-anything machines, the Ford Raptor sits atop the throne of capable off-roaders. Yes, some of this truck's utility might have been sacrificed in the name of adventure, but there aren't many complaints. The performance off-road suspension and howling 3.5L EcoBoost under the hood allow the Raptor to bound over sand dunes and tower over most water crossings right out of the dealer's lot, so what could make this machine more formidable? Well, a snorkel from Borne Off-Road, for starters.

A looming off-roader with a snorkel typically elicits visions of a truck digging through water up to its wing mirrors while triumphantly emerging out the other side, wearing the pungent mud like a badge of honor. Yes, a snorkel is what makes this possible, but only with the other necessary preparations made. First, every other part of your induction system needs to be properly sealed

Twenty-five years ago, Ford sent its Bronco moniker out to pasture. America's demand shifted from capable off-roaders to monstrous SUVs leaving Ford's purpose-built trailblazer in the dust. The Bronco has returned from the wild, however, and it's more capable than ever, sporting Ford's rock-solid 2.7L EcoBoost and a sprawling repertoire of Overlanding goodies. This feral machine might roll off the line with the equipment to tackle the wilderness, but that 2.7L Ecoboost is still carrying the same chronic illness that plagues every internal combustion engine - blow-by.

Blow-by, for those unfamiliar, is the unfortunate side effect of the internal combustion process. In short, when the fuel and air mixture ignites, combustion gasses are generated and are mostly evacuated when the exhaust valves open and ushered out by the piston. However, some gasses make their way around the piston rings and pressurize the crankcase. Breathers are incorporated into modern engine design to manage this pressure,

Air-to-water intercooling continues to be the main buzz in the realm of forced induction, and that's not without reason. This setup boasts plenty of advantages over conventional air-to-air setups, so much so that OEMs have even started rolling vehicles off the production line with air-to-water systems equipped. However, one of the main drawbacks to liquid-cooled intercoolers is the lack of universal upgrades for these systems. That's why we decided to engineer a comprehensive line of options for those looking for increased intercooling under the hood of your vehicle.

For those unfamiliar or who need a refresher on air-to-water intercooling, let's review. When your turbo or supercharger compresses air to create boost, that process heats the intake air. Hot air isn't as oxygen-dense as cold air and creates a less efficient burn in the cylinder, so it needs to be cooled, hence the intercooler. Air-to-air coolers utilize the ambient air rushing through the intercooler's fins to whisk away

Even spontaneity requires a bit of planning. These impromptu adventures that the 2019+ Ford Ranger is designed for need at least an ounce of pre-thought before taking the hard turn to a dirt path. The addition of a snorkel to your truck negates some of the preparation needed for your treks, but the snorkel still needs careful preparation.

In our last post, we covered our design plans and preparation, and now, well, let's just say we love it when a plan comes together. Our snorkel has arrived, and it's ready to raise the elevation of your 2.3L's air induction.

Before we take a look at the snorkel on the truck, though, let's look at the kit itself and what makes it tough enough to wear the Bourne Off-Road badge, starting with the construction material.

No matter how rugged

The cycle of innovation for the MK7 Golf's intake is approaching another full rotation, which can only mean one thing. Yes, we have the production level kit here in our R&D facility. We last left you with a 3D model and a sectioned-out prototype version of our design. Now though, we have the real deal, and we're stoked to show it off.

Those following this blog might have already noticed that our production kit isn't far off from the aesthetics of our fitment prototype. This is all done on purpose, of course. Adding rotational molding to our manufacturing repertoire means that we can almost perfectly recreate our prototypes in production-level form. This round, however, the kit comes clad in cross-linked polypropylene (XLPE) for maximum strength and heat resistance.

Performance is hereditary at Nissan-Infiniti. These Infiniti Q's inherited some traits from the top dog, but only the ones that count. The Nissan GT-R, in all of its "affordable supercar" status, still commands a stratospheric price point while also still being a high-strung, needy performance vehicle. So, Infiniti took that heavy-hitting performance, toughened it up for daily duty, and slapped on a much more attainable price tag. This transformation didn't come without its sacrifices, though, specifically for the intercooling system. We're already on the case to improve the Q platform, but that doesn't happen without a plan.

In our last post we covered all of the shortcomings in the VR30DDTT's air-to-water intercooling system, so now we know exactly where to start. First up is the size of the intercoolers.

Air-to-water intercoolers cram a ton

The automatic transmission in your vehicle is practically the defining feature of the vehicle. The sturdy gear sets housed inside, transferring power from the engine, are the gatekeeper to hauling heavy payloads, traversing treacherous rock gardens, or setting blistering lap times. No matter how powerful your engine is, without the transmission, your vehicle is dead weight. 

Where the transmission is the soul of your car, truck, or Jeep, keeping it cool can sometimes pose a challenge. True, there are many ways to maintain transmission fluid temperatures, but they won't do you any good if the fluid never makes it to the cooler. That's why a sturdy thermal bypass valve is essential for any automatic shifting performance vehicle.

What is a thermal bypass valve? I'm glad you asked!

These Chevy L5P Duramaxes are designed for heavy-duty. It says so right on the badges stuck on the sides of the truck. GM did its best to prepare these trucks for the constant stress of heavy payloads and long hauls, but that still takes its toll on the cooling system. Luckily we have the perfect solution.

In our last post, we revealed GM's enormous factory radiator and covered the trouble spots. How do you improve on an already gigantic radiator? Make it even more gigantic-er.

Enhancing the size of this truck radiator was a tall order, given the

After ten years, it's not much of a surprise that the 3.5L EcoBoost is still sitting at the top of the F-150 food chain. These trucks pack gobs of power with plenty of potential for more right off of the factory floor. But, with big power comes big responsibility, and it's crucial to solidify your twin-turbo V6 to reach maximum potential. We've already overhauled the F-150's intake - now it's time to wrap up the inlet pipes.

Designing intake components is always a delicate balance between fit and function. On the one hand, we want to engineer these inlet pipes for maximum flow. But, on the other hand, they still need to fit in the truck. With this in mind, our engineer, Ye, reached an equilibrium thanks to the use of rotational molded construction. This method gives Ye more freedom in the design phase when snaking our new inlet pipes through the intricacies of the Raptor's engine bay.