Mishimoto Intercooler Pipe R&D!

[Mishimoto]

Hey guys,

We've started developing a set of intercooler pipes for the EB! Check out the progress of development on our blog or posted within this thread.

http://engineering.mishimoto.com/category/ford-mustang-2-3l-ecoboost-intercooler-pipe-kit-2015/

Mustang EcoBoost Intercooler Pipe R&D, Part 1: Stock Piping Evaluation

The factory-equipped intercooler piping for the Mustang EcoBoost (EB) is a bit of a disappointment. Assuming you have popped the hood and poked around a bit, it is likely you noticed the flimsy cold-side piping and the plastic hot-side pipe that connects to the turbocharger.

Several folks have experienced boot separation from the connection points on the hot-side pipe. After evaluating the stock pipes, we highly recommend upgrading these pieces for any vehicle being modified for greater power and/or boost.

Stock Hot-Side Pipe

First, let’s take a look at the stock hot-side pipe coming off the turbocharger. As you know, this pipe routes airflow from the turbocharger to the intercooler, which is located on the passenger side of the engine bay.

Stock Mustang EcoBoost hot-side intercooler pipe

Stock Mustang EcoBoost hot-side intercooler pipe

We popped this unit off to inspect it a bit further. Three hose clamps, one electrical connection, and two push clips and this piece was out of the car.

Stock Mustang EcoBoost hot-side intercooler pipe

Turbocharger connection to Hot-side intercooler pipe

The turbocharger has a standard coupler connection, which quickly transfers into a 90-degree bend to head toward the intercooler.

Hot-side pipe connection to intercooler

The intercooler connection is 58mm (2.25”) in diameter and features a metal insert for improved rigidity and reduced chance of cracking or damaging the pipe when torquing down the clamps. This portion of the pipe connects to a short rubber coupler that mates the pipe to the intercooler.
Here is a look at the intercooler inlet.

Stock intercooler inlet

This hot-side pipe also contains the bypass valve (BPV), which works to relieve boost pressure during shifts to prevent compressor surge. The EcoBoost is electronically controlled, unlike older vehicles that use a vacuum source.

Stock EcoBoost BPV

Stock EcoBoost BPV

We will need to replicate the stock BPV flange on our pipe design to provide OEM-like fitment. This will also allow for functionality with aftermarket options that use the stock flange. If you would prefer an alternate flange, we are certainly open to recommendations.

Stock Cold-Side Pipe

The stock cold-side pipe, located on the driver side of the engine bay, routes air from the intercooler to the throttle body.

Stock EcoBoost cold-side intercooler hose

The flimsy cold-side pipe was one of the first things we noticed when we picked up our ’15 EB. This unit is not plastic or metal but is constructed from rubber for the entire length. The pipe is easily compressed by hand and should be replaced by a solid component for those seeking optimal performance and reliability.

A few shots of this hose removed:

Stock EcoBoost cold-side intercooler hose

Stock EcoBoost cold-side intercooler hose

Coming Up!

Check back next time for a look at a few 3D models featuring our prototype design as well as some work with our 3D printer to verify BPV fitment.

Thanks for reading!
-John

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[BMR Tech]

Looks good John!

 

[Mishimoto]

Looks good John!

Thanks!

 

[2015-MUSTANG]

Not familiar with IC function. So the car has gauges for water and oil temp, inlet air temp and cylinder head temp. Which of these if any will the intercooler decrease/keep in check?

 

[wireless]

None. The intercooler keeps the Charge Air Temp down (which there is not a gauge for on the OEM displays/gauges) which is post-intercooler.


You can view the Charge Air Temp. using an SCT X4, AccessPort, code reader, etc..

 

[EcoSwag1990]

Not familiar with IC function. So the car has gauges for water and oil temp, inlet air temp and cylinder head temp. Which of these if any will the intercooler decrease/keep in check?

If you're having heat mngmt issues though they do have an oil cooler on the market already and a radiator upgrade on the way

 

[Mishimoto]

Not familiar with IC function. So the car has gauges for water and oil temp, inlet air temp and cylinder head temp. Which of these if any will the intercooler decrease/keep in check?

None. The intercooler keeps the Charge Air Temp down (which there is not a gauge for on the OEM displays/gauges) which is post-intercooler.

You can view the Charge Air Temp. using an SCT X4, AccessPort, code reader, etc..

Thanks Wireless, that is correct. An intercooler upgrade will impact manifold (Charge-Air) temperatures, a very important data point for a modified vehicle.

If you're having heat mngmt issues though they do have an oil cooler on the market already and a radiator upgrade on the way

Thanks! Our oil cooler is a nice option for vehicles seeing track use or aggressive street driving. The stock EB does not come factory-equipped with an oil cooler.

Our radiator design is shaping up and we have been conducting some initial testing this week. We will be starting an R&D thread on the forum soon!

Let us know if we can answer any additional questions!

-John

 

[2015-MUSTANG]

I ve added a tune to my otherwise stock vehicle. I was wondering what to look for as an indication my stock intrrcooler was not sufficient.

 

[wireless]

I don't know if you can view it with the LMS tuner, but normally you view your charge air temps.

 

[mtpavelka]

I don't know if you can view it with the LMS tuner, but normally you view your charge air temps.

You can't view anything with the LMS tuner. All you can do is load a tune. Beyond that it serves no other purpose

But you can view IAT right from the Guage Mode which I thought was post IC. I could have been wrong about that tho.

 

[wireless]

No sir -- the IAT is pulled from the intake air temp (post air filter)

 

[Mishimoto]

Quick project update guys!

Mustang EcoBoost Intercooler Pipe R&D, Part 2: 3D Models and BPV Port Prototyping

3D Pipe Models

As with all our projects, we would be using 3D modeling software (Solidworks) to put our final design into both 3D and drawing forms. Not only does this put our design into a viewable format, but it also allows for digital tweaks as well as confirmation of fitment and precision with the overall product design.

Check out the rendering below showing our projected cold-side pipe design.

Mishimoto cold-side intercooler pipe 3D model

Ford made this one fairly easy for us. This pipe features a pretty smooth shape and routes from the intercooler to the throttle body. An aluminum counterpart is going to be a huge improvement over the stock rubber hose referenced in the last post. Each connection point will be secured with a Mishimoto silicone coupler and our T-bolt clamps for a solid connection. Note the bead roll on the end of our pipe for added holding strength for the coupler.

One additional feature you may notice is the bung on the top of the pipe. We are including this bung on the pipe for use with meth injection or as an additional pressure/temperature sensor. This bung is not predrilled, but it does provide the option for users who require it. Pretty slick!

On to our hot-side pipe model.

Mishimoto hot-side intercooler pipe 3D model

The hot-side pipe presented a bit more of a challenge in terms of emulating the stock pipe. The shape was rather simple to replicate, but that pesky BPV flange was quite a challenge. We wanted our pipe to be completely compatible with the stock BPV unit so we would have a bolt-on upgrade.

To do this we collected dimensional information on the stock piece so we could design this component in 3D.

We then utilized our 3D printer to print the flange we designed so we could confirm fitment with the stock BPV unit. Check out the prototype!

3D-printed BPV flange prototype

3D-printed BPV flange prototype

3D-printed BPV flange prototype

Once printed, we fit this unit to the stock BPV to ensure proper fitment. With all dimensions confirmed, we were ready to construct a set of final prototype pipes to give this kit the thumbs up for mass production.

Coming Up!

Check back next week for a look at our final pipes and information regarding our discounted presale for this awesome kit!

Thanks
-John

 

[Mishimoto]

Project update! Check back later today for information in regards to our discounted presale.

Mustang EcoBoost Intercooler Pipe R&D, Part 3: Final Pipe Design and Test Fit

After putting some final touches on our pipe design in 3D modeling software, we concluded the design phase of this project. With only inspection of our final prototype and final test fitting on the agenda, this project was nearly complete.

Final Prototype Pipe Kit

Check out a look at the final prototypes we worked up!

Mishimoto hot-side (left) and cold-side (right) intercooler pipes

Mishimoto hot-side (left) and cold-side (right) intercooler pipes

Mishimoto hot-side (top) and cold-side (bottom) intercooler pipes

As noted previously, these pipes are constructed from aluminum, mandrel-bent piping. This will provide the rigidity and smooth flow you want within your CAC system.

Our cold-side mounted bung is shown below.

Mishimoto cold-side intercooler pipe bung

Next, take a look at the BPV flange we developed in order to provide bolt-on fitment with all stock equipment.

Mishimoto hot-side intercooler pipe with BPV flange

Mishimoto hot-side intercooler pipe with BPV flange

And here’s a look at our CNC-machined piece compared to the stock flange!

Mishimoto hot-side intercooler pipe BPV flange (left) and stock BPV flange (right)

Full Kit

These pipes are useless without a set of couplers to secure them to the appropriate points. As with our other intercooler setups, we will use 4-ply silicone couplers for durability and tolerance. Check out a few shots of the included couplers for both the hot-side and cold-side pipes.

Mishimoto intercooler couplers

And here’s our full kit including the couplers and pipes!

Mishimoto Mustang EcoBoost Intercooler Pipe Kit

Final Test Fit

Once installed, these pipes look fantastic and are a huge improvement in aesthetics compared to the stock CAC hoses/pipes. This, alongside the improvements in pressure tolerance, are reason enough to make the upgrade to an aluminum CAC piping system. If you are planning on intake, exhaust, or tune upgrades that boost power, we highly recommend replacing the stock pieces.

Here’s a look at the cold-side pipe being installed.

Cold-side intercooler pipe installed

And here’s our hot-side pipe being installed!

Hot-side intercooler pipe installed

The last key component is the install of the stock BPV unit on our pipe.

Hot-side intercooler pipe with BPV installed

Everything within this kit fit perfectly and easily handled our road-driven torture test. This kit is good-to-go and will be available soon!

Intercooler Kit Presale

As with most of our new products, we are planning to launch a discounted presale for folks interested in purchasing this kit. We will be offering these pipes in both a polished finish, shown in this post, as well as a wrinkle-black finish for those seeking a more discreet upgrade.

More information on our presale, including pricing and ship date, coming on Monday 5/18!

Thanks for reading!
-John

 

[Mishimoto]

Our discounted presale is live! Check out the details below.

Pre-Sale Link!!



Mishimoto 2015 Ford Mustang EcoBoost Intercooler Pipe Kit

Pre-Sale Price:

Cold-Side: $149.95
Hot-Side: $214.95
Full Kit: $349.95

MSRP:

Cold-Side: $215.00
Hot-Side: $295.00
Full Kit: $485.00

Pre-Sale Expiration Date: 6/26/2015

Estimated Ship Date:

Polished: 6/26/2015
Wrinkle-Black: 7/15/2015


Finish Options:
Polished
Wrinkle-Black

Product Specs

• Direct fit for the 2015+ Ford Mustang EcoBoost
• Replaces weak stock hot-side plastic intercooler pipe and rubber cold-side intercooler hose
• CNC-machined BPV flange allows for quick install of stock or stock-style BPVs
• Installs in under 30 minutes
• Pre-marked CNC-machined area allows for quick install of meth injection or a boost gauge
• Lightweight, mandrel-bent aluminum pipe
• Fits both stock and Mishimoto Performance Intercoolers
• Available with a polished or wrinkle black finish
• Includes Mishimoto Silicone couplers and Mishimoto T-Bolt Clamps
• Mishimoto Lifetime Warranty

Additional Images








Product R&D
http://engineering.mishimoto.com/category/ford-mustang-2-3l-ecoboost-intercooler-pipe-kit-2015/

Tech Specs


Pre-Sale Link!!

Feel free to follow-up with any questions regarding this kit!

Thanks
-John

 

[stormtrooper]

I can put the full kit on and it wont effect my Intake I already have on it right??

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