Mishimoto Downpipe R&D

[Mishimoto]

Hey guys,

We've started development of our downpipe for the 2015 Mustang EB! Follow our R&D progress on our blog or posted within this thread!

http://engineering.mishimoto.com/category/ford-mustang-ecoboost-downpipe-2015/

Unleashing The EcoBoost – Downpipe Development, Part 1: Stock Component

Opening up the exhaust on a turbocharged vehicle is a great first modification that can make a big impact on drivability, vehicle sound, and driver enjoyment. Typically, a vehicle will see improvements in horsepower and massive gains in torque output. Emissions and sound requirements normally restrict the size and efficiency of stock exhaust systems, which explains why big gains result from enlarging the piping and eliminating or reducing restrictions within the piping.

For this project, we will focus our efforts on designing and testing a new downpipe option for the 2015+ Ford EcoBoost Mustang. Before tackling our downpipe design, we will take a look at the stock unit pulled from our Triple Yellow shop vehicle.

Stock Downpipe Features
If you haven’t peeked under your new Mustang, this portion of the article will give you a look at what the stock vehicle is equipped with in terms of the downpipe.

Stock 2015 EcoBoost downpipe

The downpipe mates the turbocharger to the rest of the exhaust system. This component runs from the passenger side of the engine bay down under the vehicle and connects with the rear portion of the exhaust right behind the transmission.

Stock 2015 EcoBoost downpipe

Stock 2015 EcoBoost downpipe

The stock downpipe is rather easy to access and remove; six bolts and some shimmying, and the pipe is out. It is almost as if Ford designed this component with the implication that it would be tossed to the side for a larger unit.

Once out, we can get a closer look at the individual components.

Stock 2015 EcoBoost downpipe removed

Stock 2015 EcoBoost downpipe removed

Now, let’s go through each component/feature of this pipe.

Turbocharger Flange

Stock downpipe turbocharger flange

The stock turbocharger flange is a pretty unique setup. The Mustang utilizes a two-bolt, ball-style flange. Typically with modern downpipes, we see a multiple bolt (four to five) flat flange that mounts to the turbocharger exhaust housing.

Check out a side-view profile of this connection.

Stock downpipe turbocharger flange

The inner diameter of the pipe measures 2.75” from this flange until it meets with the catalytic converter. After the converter the piping measures 2.5” up to the flex joint. Following the flex joint, the pipe tapers to 2.25” to mate with the rear portion of the exhaust. We should have no problem increasing the size of this with the allotted space on this vehicle.

Stock downpipe turbocharger flange diameter

Oxygen Sensors and Catalytic Converter
As with most modern four-cylinder engines, the EcoBoost features two oxygen sensors that are both plumbed into the downpipe.

First oxygen sensor

The second oxygen sensor is positioned within the catalytic converter assembly.

Second oxygen sensor

Flex Joint
The flex joint is toward the rear of the downpipe. This component allows the pipe to flex, which reduces the chances of cracking or damage from engine movement during acceleration. As with the flanges, this flex assembly is fairly unique compared to what we normally see on exhaust systems.

Stock downpipe flex joint

Rear Exhaust Connection
The last portion is the rear connection point, where the downpipe attaches to the rest of the exhaust system. We typically see a flanged connection here; on the Mustang, however, we have a pretty slick slip-joint.

Stock downpipe slip-joint

Data Collection
Now that we had an idea of what we were getting ourselves into from a development standpoint, we needed to collect dimensional information from the stock pipe so we could begin working on our design. We placed the stock pipe on the Coordinate Measuring Machine (CMM) table and set our engineering team to work.

Stock downpipe on CMM table

Stock downpipe on CMM table

Stock downpipe on CMM table

On The Horizon
We have big plans for this downpipe. Check back with us next time for a look at our 3D renderings and an explanation of our design and features.

Thanks for reading!
-John

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[midnite9150]

I love how detailed you guys get in your r+d threads

 

[mtpavelka]

I love how detailed you guys get in your r+d threads

x2

 

[ronv95]

I see a lot of business going your way from the people who have been waiting on doing mods until more options are available. You guys really do a great job on providing detailed threads on all your products from start to finish. I enjoy reading your threads regardless if I already have a competitors product or not.

 

[cosmo]

Woo, I love mishimoto stuff. Waiting on your intercooler, and will end up going with your downpipe if you offer a catted one.

 

[Mishimoto]

I love how detailed you guys get in your r+d threads

x2

I see a lot of business going your way from the people who have been waiting on doing mods until more options are available. You guys really do a great job on providing detailed threads on all your products from start to finish. I enjoy reading your threads regardless if I already have a competitors product or not.

Woo, I love mishimoto stuff. Waiting on your intercooler, and will end up going with your downpipe if you offer a catted one.

Thanks for the kind words guys! We put a lot of time into both product development and the creation of these threads. We appreciate the comments.

We certainly have plans for both a catted and catless pipe!

More details on development coming soon.

-John

 

[bigspoondude]

I think you guys need to make some vehicle badging, as I might have more Mishimoto parts than Ford parts on my car. Are you guys going to be offering cat and catless varieties?

 

[Mishimoto]

I think you guys need to make some vehicle badging, as I might have more Mishimoto parts than Ford parts on my car. Are you guys going to be offering cat and catless varieties?

Badging is typically outside of our product realm but certainly not out of the question. We do intend to offer both a catted and catless option for this downpipe.

Thanks
-John

 

[paullyd210]

Any Updates?

 

[Mishimoto]

Any Updates?

Thanks for the interest! This project is certainly moving along. We will have a development update up before the end of next week.

-John

 

[TRACK-STANG]

Any update on the down pipe?

 

[Impulsed7]

Also interested in a catted downpipe.

As far as badging, just design a well thought out decal in a badge size. It works and its lightweight (ala porsche GT3 badges).

 

[Mishimoto]

Any update on the down pipe?

Also interested in a catted downpipe.

As far as badging, just design a well thought out decal in a badge size. It works and its lightweight (ala porsche GT3 badges).

Thanks guys! We should have an update on this project early next week. Things are moving along quite nice.

-John

 

[Mishimoto]

Project update!

Unleashing The EcoBoost. Downpipe Development, Part 2: 3D Printing and Initial Prototype

Mishimoto downpipe 3D model

It has been awhile since our last update on the Mishimoto downpipe, however I assure you it was worth the wait. We have had our engineers tackling a ton of awesome new products for the EB, this exhaust system included. We left off with an evaluation of the stock downpipe. Once that was complete we set out to design our own system.

3D Printing
Is Mishimoto going to print out an entire downpipe? Not entirely, but we do intend to flex the muscles of our new 3D printer on this particular project. If we have the technology, why not use it. After creating a model of our design in Solidworks, we began to print components that would require additional time to fabricate. This includes bungs, flanges, and bends within the system.

Check out a shot of our printer pumping out one of the bends on our design.

3D printing of prototype components

3D printing of prototype components

3D printing of prototype components

Once out of the printer we needed to clean up the parts and file down some portions of the support material.

3D-printed prototype components

3D-printed prototype components

First Prototype
With our components printed, we could then combine this with piping to match our design, allowing us to put together a prototype for test fitting.

Mock-up of downpipe prototype

In the foreground we see the flange that meets the cat-back portion of the exhaust system. This follows the same path as the stock downpipe. We are using the stock exhaust hanger points, which you see mounted to this flange piece. Now, a look from the top.

Mock-up of downpipe prototype

This pipe reflects our catless design; we will also be offering a catted pipe. From this image you can see three oxygen-sensor bungs on the pipe. The first sensor is located in the exact location of the stock unit, while the second sensor has been placed slightly more downstream. This is done to account for a catalytic converter in between the first and second sensors.
The third sensor bung is an added feature with our pipe. As you may be aware, the stock pipe uses only the first two sensors. Our third sensor has been included for folks interested in adding a wideband oxygen sensor to monitor air/fuel ratios.

Mock-up downpipe prototype

This last image shows the flange that mates to the turbocharger exhaust housing. We have modeled our design to the exact specifications of the stock flange for flawless fitment.

Test Fitting
Now that we had our prototype put together, it was time to install this unit and check for clearances. If we find any issues at this point they can be easily corrected before we construct a functional prototype. Check out how this unit fits into place.

Downpipe prototype installed

Downpipe prototype installed

The prototype mated up perfectly with the stock turbocharger housing as well as the front downpipe mounting point.

Downpipe prototype installed

Downpipe prototype installed

Downpipe prototype installed

3D Models
After inspecting this prototype fully installed, we made a few minor adjustments to our design and moved forward with producing a functional prototype. In the meantime, check out some cool 3D models showing our downpipe.

Catless Downpipe

Mishimoto catless downpipe 3D model

Mishimoto catless downpipe 3D model

Mishimoto catless downpipe 3D model

Mishimoto catless downpipe 3D model

A few more interesting features to note! Toward the end of the pipe near the cat-back connection you will notice a slight bulge within the pipe, which is an intended flex joint. Exhaust flex is important to consider with our design. A rigid system without play may end up with cracked welds or damage as the engine moves during acceleration.

At the cat-back flange you will notice a neck-down piece in place to mate with the stock slip joint. This flange is connected to our exhaust with a V-band. We are working on a cat-back system that will mount directly to our V-band on the end of this downpipe. This allows for compatibility with both the stock cat-back as well as our future 3” design.

Catted Downpipe
The downpipe equipped with a catalytic converter is very similar to the previous design, but with the converter placed within the confines of the front mounting bracket. Check out a few more renderings!

Mishimoto catted downpipe 3D model

Mishimoto catted downpipe 3D model

Mishimoto catted downpipe 3D model

Mishimoto catted downpipe 3D model

Coming Up!
Our next task is to construct a functional prototype for test fitting, sound testing, and power output tests. Check back soon for more details on this!

Thanks for reading!
-John

 

[jbailer]

Any update John?

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