A New Intake Option!

[Mishimoto]

Hey guys,

We are working on the development of an intake system for the EB Mustang. Follow the progress of this project on our blog or posted in this thread!

http://engineering.mishimoto.com/category/ford-mustang-2-3l-ecoboost-performance-air-intake-2015/

The EcoBoost Intake Project, Part 1: Stock Intake System

Fresh Air
An intake is a great way to dip your feet into the aftermarket modification pool. Easy to install, instant results, and a neat sound are key draws for upgrading this particular component. Depending upon the form of engine management and airflow sensor use, slight power gains are often a result of upgrading to a less restrictive system.

The new EcoBoost Mustang is slightly different than other intake projects we have tackled, which have been mainly Subaru MAF-style intake systems. As you know, the EB is a MAP-based system, so intake upgrades normally make less of an impact on power but still provide that same intake noise/growl you expect. Additionally, upgrading the intake for greater flow will provide less restrictions for vehicles that are further upgraded (exhaust, tune, turbocharger, etc.).

With all this in mind, we set out to create a unique intake system for the Mustang. We will be fully testing this unit to see if any power gains could be obtained, and we will be providing video of the sound amplification our design generates.

Stock Intake System
Before jumping into fabrication, we would need to take a look at the stock intake system to see where we should start with our design. This would also give us the chance to check for any components and features needed on our intake.

EcoBoost Mustang stock intake system

The intake is rather similar to other modern systems. It features plastic piping leading from the turbocharger compressor inlet to the airbox on the driver side of the engine bay. A few couplers are installed on the pipe to allow for flex during engine movement. We then popped off the intake box top to reveal the filter.

EcoBoost Mustang stock intake system

The stock intake utilizes a pretty standard panel air filter. While great at filtration, these units are not normally serviceable (other than blowing them out with compressed air), and they are typically a bit more restrictive than an aftermarket filter. Next, we removed the airbox completely.

EcoBoost Mustang stock airbox

The stock airbox pulls airflow from the front grille area, which is then funneled through the box and filter. You can see a Helmholtz resonator toward the beginning of the scoop in the image above. This resonator will provide a cavity for airflow moving backward in the intake system, and it will also work to reduce noise. The AIT sensor, which simply reads the temperature of the air, can be found on the upper portion of the box. A more antiquated MAF system would have a larger sensor in this area. After taking an in-depth look at this unit, we removed the stock intake piping.

EcoBoost Mustang stock intake pipe

EcoBoost Mustang stock intake pipe

This piping is rather simple and includes just two ports: one for the CCV breather system, the other for the bypass valve. The turbo inlet side measures at 2.3” and gradually increases to 3.75” where it connects to the airbox. We then removed the stock system completely to begin the development of our intake system.

Intake removed

Intake removed

Intake removed

Our team decided to start our design at the turbo and work toward the box location. We began by modeling the stock intake pipe in 3D using our Romer arm to collect dimensions.

Stock intake 3D modeling

Check back with us next week for more details on the design of our intake pipe!

Thanks

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[stoli]

Gotta give you guys props for the way you detail these projects from start to finish; I have to say it's quite a change from the norm with most after market companies.

To top it off, you set fair expectation with statements like:

With all this in mind, we set out to create a unique intake system for the Mustang. We will be fully testing this unit to see if any power gains could be obtained, and we will be providing video of the sound amplification our design generates.

No claims or promises of huge gains, or any gains for that matter, just plain and simple 'let's see what happens'.

Great work!

 

[Voodoo1796]

Intake box looks a lot like the Speed3 setup...It would be interesting to see if you would get the Speed3 like gains from just an intake.

 

[EcoSnake]

I've been wondering.... Since you are working on this. Is it possible to route it to the shorter passenger side? Instead of just hooking to the 5.0 box/area like Ford did to save costs?

 

[BGolden]

The stock tubing has a pretty good design. We found the filter and box limited the intake more than the tube. Interested to see the results

 

[Herr_Poopschitz]

I've been wondering.... Since you are working on this. Is it possible to route it to the shorter passenger side? Instead of just hooking to the 5.0 box/area like Ford did to save costs?

Agreed, relocate a few things and short tube?

 

[EcoSnake]

Agreed, relocate a few things and short tube?

Yes, and I think the eye sore needs to be hidden inside the old air box lol.

 

[Mishimoto]

Gotta give you guys props for the way you detail these projects from start to finish; I have to say it's quite a change from the norm with most after market companies.

To top it off, you set fair expectation with statements like:

No claims or promises of huge gains, or any gains for that matter, just plain and simple 'let's see what happens'.

Great work!

Awesome, thanks for the kind words! We are certainly hoping for some gains but that will be determined when we have our full prototype completed.

Feedback on our products and posts is always welcome! Thanks buddy.

Intake box looks a lot like the Speed3 setup...It would be interesting to see if you would get the Speed3 like gains from just an intake.

We shall see! Once our prototype is completely designed we will be putting the car on the dyno for some testing.

I've been wondering.... Since you are working on this. Is it possible to route it to the shorter passenger side? Instead of just hooking to the 5.0 box/area like Ford did to save costs?

Agreed, relocate a few things and short tube?

Yes, and I think the eye sore needs to be hidden inside the old air box lol.

Certainly a decent option/idea guys. Do keep in mind that the air scoop from the front grille is located on the drivers side of the vehicle. The passenger port is blocked off but I assume that could be remedied by removing some plastic components.

The stock tubing has a pretty good design. We found the filter and box limited the intake more than the tube. Interested to see the results

Yes, the tubing is reasonably large and follows a pretty smooth path. The airbox is typically more restrictive on a stock setup. We will be designing our own airbox to prevent any filter heat soak.

 

[Mishimoto]

Project update! Check it out below.

The EcoBoost Intake Project, Part 2: Prototype Piping

With the stock unit out of the way we could begin developing our intake piping. We would be starting at the turbocharger and working outward to an airbox near the stock location.

Using the dimensions from the stock unit, we developed a 3D model of an inlet hose that would be constructed from a silicone material. After completing the model, we produced a unit using our 3D printer.

Printing 3D model of intake inlet tube

Because this piece is larger than the bay of our 3D printer, it was constructed from three sections that were glued together. Check out the final design!

3D model of intake inlet tube

3D model of intake inlet tube

This unit has a shape that is similar to the factory unit. We also incorporated both the BPV and the CCV ports, which allow for connection to the OEM pieces. This unit will install just like the factory piping.

This component would be constructed from wire-reinforced silicone. The internal steel wire is in place to prevent collapse under vacuum and suction. Our CCV and BPV ports will be CNC-machined aluminum pieces that will be molded into the silicone hose, creating a leak-free seal. Additionally, using silicone for this inlet portion will allow engine twisting under load.

Check out our WRX induction hose that features this wire-reinforced silicone.

Wire-reinforced silicone example

Next, we installed this component to check fitment so we could begin mocking up the rest of the piping.

Inlet prototype installed

We then began fabricating the piping that would lead to an airbox location on the driver side of the engine bay.

Intake pipe fabrication

Check out the progress of mocking this unit into place.

Intake pipe mockup

Intake pipe mockup

Intake pipe mockup

The only addition still needed for this pipe was an IAT (intake air temperature) sensor bung that would function with the stock sensor. We were pleased with the pipe and routing, so we placed this unit on our CMM (coordinate measuring machine) table to collect dimensions for a 3D model of the pipe we created for this kit.

Intake pipe on CMM table

Now, all we had left was to create the airbox we envisioned at the start of this project. Check back with us next time for a look at how we designed it! For now, we leave you with a teaser rendering of this setup.

Mishimoto intake rendering

Thanks!

 

[mtpavelka]

That's pretty cool to see the design process. Looking good.

 

[Mishimoto]

That's pretty cool to see the design process. Looking good.

Thanks for taking a look! :cheers:

 

[kevg73]

I'm curious what the purpose is of the last bend down right before the filter. Most of the other intakes don't have this bend and the filter ends up being roughly parallel to the ground instead of pointed down like yours. Is this to put the filter more directly in front of the intake cutout in the grill?

 

[Mishimoto]

I'm curious what the purpose is of the last bend down right before the filter. Most of the other intakes don't have this bend and the filter ends up being roughly parallel to the ground instead of pointed down like yours. Is this to put the filter more directly in front of the intake cutout in the grill?

Great question Kev! The last bend allows us to place the filter right in front of the grille duct, providing the greatest amount of airflow possible. Additionally, it pushes the filter as far away from the hot engine as we could, while still keeping it within the engine bay. The bend also fits within our airbox design which is shown in the last image and will be highlighted further in a post next week.

Thanks for the inquiry!

 

[ECOKN815]

Great question Kev! The last bend allows us to place the filter right in front of the grille duct, providing the greatest amount of airflow possible. Additionally, it pushes the filter as far away from the hot engine as we could, while still keeping it within the engine bay. The bend also fits within our airbox design which is shown in the last image and will be highlighted further in a post next week.

Thanks for the inquiry!

Had the same question, excellent write up and really impressed with the transparency Mishimoto has been conducting on the forumn. I read somewhere a dry filter would work best than an oiled filter for a turbo? Any real preferance to either filter and with the fitment of your design would the filter be in harms way of water/dirt etc.

Thanks!

 

[Mishimoto]

Had the same question, excellent write up and really impressed with the transparency Mishimoto has been conducting on the forumn. I read somewhere a dry filter would work best than an oiled filter for a turbo? Any real preferance to either filter and with the fitment of your design would the filter be in harms way of water/dirt etc.

Thanks!

Thank you very much for the kind words! Filter preference will certainly vary depending upon the customer. Performance will be very similar between a dry and oiled unit, the primary difference is in terms of serviceability. An oiled filter is cleanable, meaning it is essentially the only filter needed for the life of the vehicle. A dry filter can be blown out with compressed air, however this will only remove larger debris from the cotton media.

Great question about the concern with oiled filters. Over the years, a few folks have come forward with issues regarding oiled filters fouling out engine sensors due to the oil dislodging from the filter and coating the sensor. As long as the filter is serviced properly, and is oiled with the appropriate amount of fluid, the engine sensors should not be impacted in any way. In fact, the actual impact of filter oil on sensors is another debatable topic that I will not get into. The typical issue revolves around the MAF sensor, which uses a heated wire or vane to determine airflow. As we know, the EB does not utilize a MAF sensor. This kit will utilize our oiled air filter which we have had a ton of success with on our other intake kits.

Our design should not encounter any more dirt/water than the factory setup would. The stock snorkel provides a slightly restrictive opening which is eliminated in our design. As long as you are not wading through rivers in your EB, we do not anticipate any issues.

Thanks for the interest!

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