Page 89 - Engineering

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Mishimoto Mustang EcoBoost Performance Intercooler

Will this cooler be efficient enough to properly handle the heat and pressure created by the EcoBoost? Will we see any power gains during testing? These questions will be answered in the next few minutes, perhaps even quicker if you get scroll happy and skip ahead. Don't ruin the suspense!

Stock Intercooler Testing

First, we would need to capture data from the stock intercooler. We installed bungs on both the hot- and cold-side couplers for our pressure and temperature sensors.

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Mishimoto Subaru WRX Front-Mount Intercooler Kit

Front-mount intercooler installed

In the last portion of this series we completed the fabrication of our prototype intercooler core and tanks, as well as our new bumper beam. We now had everything in place to construct a piping kit that would route air from the turbocharger to the intercooler and back to the engine.

Hot-Side Piping

We started our piping with the hot-side of the intercooler system. The stock compressor

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Mishimoto Jeep Wrangler YJ and TJ Performance Fan Shroud Kit

Jeep YJ in Mishimoto shop

Project Intro

After a few successful electric fan conversion projects, we chose yet another vehicle that could benefit from the removal of the stock clutch fan. Our previous endeavors involved BMWs that experienced frequent failures of the plastic stock clutch fan. After checking through potential applications and scouring the forums, our team chose the Wrangler as a prime subject for a reliable and efficient electric fan

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Mishimoto Ford 6.4L Powerstroke Coolant Filter Kit

Final Prototype Bracket

Welcome back! Our final bracket prototype is in and ready for installation. Check it out!

Mishimoto 6.4L coolant filter bracket

Mishimoto 6.4L

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Mishimoto Subaru STI Performance Air Intake

As noted earlier in this article series, we would be tackling a race intake system to go along with our bolt-on unit. So what makes the race system different? For this particular system we are using a larger-diameter intake pipe with a larger MAF housing. This means greater intake flow, but it also means it will no longer function with the factory tune. This system is meant specifically for drivers who want aggressive professional tunes so they can take advantage of airflow modifications such as larger turbochargers and high boost pressures.

Because the 15' model shares the EJ from the previous generation, we would be using the same intake pipe and filter as we did with our 2008-2014 kit. This unit is shown below.

So, all we truly needed

Interested in picking up this awesome Mustang EcoBoost Intercooler? Check out our product page for more details!

Mishimoto Mustang EcoBoost Performance Intercooler

An Interesting Discovery

At this point, our intercooler project took an interesting turn. We wanted to develop a cooler, including going through the process of 3D design, and working up a prototype unit. That said, we had a new idea to get some early baseline testing for core design.

After swinging by our sample room, we retrieved the cooler shown below.

Mishmoto E90 intercooler

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Mishimoto Ford Mustang EcoBoost Performance Air Intake

Last time we covered the design of our intake pipe and left you with a look at our airbox design in the form of a rendering. It's time to show you how we developed this component.

First, we started with some steel and began selecting mounting points for attaching our box. Once we found these points, we pulled out the welder and began fabricating a prototype.

Fabricating Mustang airbox

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Mishimoto Subaru WRX Front-Mount Intercooler Kit

Crash Beam Fabrication

After an unsuccessful test fit of our existing bumper beam on the 15', we started from scratch to create a beam specific for the 15' chassis. First we hacked off the end tanks of our cooler so we were left with a bare core. This would provide some freedom to design our crash beam and later work on the end tank direction. Next we cut out some new mounting plates and fit them into position.

Intercooler

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Subaru WRX Baffled Oil Catch Can System

Subaru STi Baffled Oil Catch Can System

Mishimoto 2010 STI

After developing a highly successful, direct-fit catch can setup for the 2015 WRX we turned our attention to the previous generation. Our next target would be the 2008-2014 WRX and STI. At this point, Mishimoto still owned a 2010 STI, and this project would be our last for our shop vehicle.

Catch Can Selection

As with our 2015 WRX