Renner
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Sub'd for more details and some videos 
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Mishimoto
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- Thread starter
- #34
Sure do! The first page of this thread highlights our current progress in developing this intake.
http://www.mustang6g.com/forums/showpost.php?p=439270&postcount=9
We will have another update later today!
Thanks
OP
OP
Mishimoto
Well-Known Member
- Thread starter
- #35
Time for an update! Check it out.
The EcoBoost Intake Project, Part 3: Airbox Design
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
Fabricating Mustang airbox
We then constructed a lid to fully seal the filter from engine bay temperatures.
Fabricating Mustang airbox
Fabricating Mustang airbox
Now that we had a basic design, our engineering team put this into Solidworks to create the awesome 3D renderings shown below.
Mishimoto intake system rendering
Mishimoto intake system rendering
We didn’t stop here! To ensure the perfect fitment of this component, we used our 3D printer to construct an actual prototype from our 3D renderings. This unit was printed in several sections and glued together.
The external ribs you see running across the surface are specifically included to strengthen the plastic construction. They will not be needed in the final airbox design.
3D Printed airbox
3D Printed airbox
3D Printed airbox
3D Printed airbox
And here’s the printed unit next to our drawing!
3D Printed airbox and drawing
Next we installed this prototype in our Mustang to confirm fitment. Check it out!
3D Printed airbox installed
3D Printed airbox installed
3D Printed airbox installed
3D Printed airbox installed
Now that we had a functional prototype it was time for the fun part, product testing! Check back with us next time for a look at dyno testing and the results!
Thanks
The EcoBoost Intake Project, Part 3: Airbox Design
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
Fabricating Mustang airbox
We then constructed a lid to fully seal the filter from engine bay temperatures.
Fabricating Mustang airbox
Fabricating Mustang airbox
Now that we had a basic design, our engineering team put this into Solidworks to create the awesome 3D renderings shown below.
Mishimoto intake system rendering
Mishimoto intake system rendering
We didn’t stop here! To ensure the perfect fitment of this component, we used our 3D printer to construct an actual prototype from our 3D renderings. This unit was printed in several sections and glued together.
The external ribs you see running across the surface are specifically included to strengthen the plastic construction. They will not be needed in the final airbox design.
3D Printed airbox
3D Printed airbox
3D Printed airbox
3D Printed airbox
And here’s the printed unit next to our drawing!
3D Printed airbox and drawing
Next we installed this prototype in our Mustang to confirm fitment. Check it out!
3D Printed airbox installed
3D Printed airbox installed
3D Printed airbox installed
3D Printed airbox installed
Now that we had a functional prototype it was time for the fun part, product testing! Check back with us next time for a look at dyno testing and the results!
Thanks
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greg hazlett
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Is your intake going to be metal or plastic?
greg hazlett
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Thanks!
Trackaholic
Well-Known Member
Love reading these design journals. Thanks for putting them together.
-T
-T
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midnite9150
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3D printing is so damn cool
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Mishimoto
Well-Known Member
- Thread starter
- #43
This project is complete! Check out the testing details and final product in the post below!
http://engineering.mishimoto.com/category/ford-mustang-2-3l-ecoboost-performance-air-intake-2015/
The EcoBoost Intake Project, Part 4: Testing Data & Final Product
Mishimoto intake installed
After wrapping up the design of our intake for the 2015, it was time to put the car on the rollers to see if we were making any power gains. As mentioned earlier in this series, we believed that significant power gains were unlikely due to the MAP-based ECU, which is not normally affected by modified intake systems.
Dyno Testing
With that in mind, we strapped the Mustang down and made a few pulls.
2015 Mustang EcoBoost on the dynamometer
[ame]
Testing Results
After making several pulls with both the stock intake and Mishimoto intake, we averaged the runs, and the results are shown in the plot below.
Dyno results for Mishimoto and stock intakes
Although we were a bit skeptical about power gains for this vehicle, we did end up with some nice increases throughout most of the RPM range. These gains are likely due to the reduced restriction caused by the stock airbox system. We saw 4–8 whp gains from about 3,500 rpm through redline. Torque benefits were similar and peaked around 9 wtq at 5,500 rpm.
It is extremely likely that additional modifications and tuning will provide even greater gains with our intake system, thanks to the free-flowing filter and piping design.
We are very pleased with these results. Not only did the vehicle make some decent power gains, but we also really liked the improved tone provided by the intake setup. Spool noise is greatly amplified and sounds terrific both inside and outside of the vehicle.
Filter Surface Area
Along with dyno pulls, we performed some comparison analyses of the stock air filter versus the Mishimoto unit we would be using with our kit.
Comparison of air filter surface areas
Air filter surface area is one of the features we like to compare when looking at the stock intake system. So what is the benefit of greater surface area? Greater filter surface area significantly increases the potential CFM of our filter. More air passages will provide less restrictions, especially for modified vehicles moving more air than a stock vehicle.
Silicone Inlet Hose
Another interesting update for this project is the arrival of our final prototype for the silicone inlet hose. We have been discussing this part for quite some time, and we have posted some 3D-printed prototype images. Check out this unit in its final form!
Mishimoto silicone inlet hose
Mishimoto silicone inlet hose
The next image shows a more detailed shot of our CNC-machined fittings that are molded into the hose.
Mishimoto silicone inlet hose with CNC-machined fittings
The final shot shows the thickness of this hose and the fibers that are embedded with the silicone we use to manufacture this piece.
Mishimoto silicone inlet hose thickness
Intake Piping
Along with our finalized silicone piece, our intake piping was also completed. Check out a few shots.
Final prototype of intake piping
Final prototype of intake piping
Final prototype of intake piping
A few details about this pipe. This unit is constructed from mandrel-bent aluminum, and it features smooth bends to route air from our airbox to the turbocharger inlet. We utilize a bracket to stabilize the pipe and prevent vibration. The bung mounted to the top of the pipe mates perfectly with the stock sensor for the intake air temperature (IAT).
Not a fan of the polished look? Don’t worry, we will be offering this piping in a wrinkle black finish as well. We are also considering a blue (Ford) finish of some sort, so let us know if this interests you and perhaps we can give it a run!
We finish off the end of this piping with our Mishimoto oiled air filter.
Mishimoto air filter
Completed Airbox
The airbox is a key component that helps reduce the effect of engine bay heat on our filter and on air temperatures. You saw our 3D-printed unit earlier; check out the final design below.
Final prototype of intake box
Final prototype of intake box
We also created an easily removable lid for servicing of the filter.
Final prototype of intake box
This box is constructed from powder-coated steel and works to properly isolate the air filter. This unit mounts to existing points within the engine bay and provides a stock-like appearance.
Fully Installed Kit
And check out this kit fully installed in our EB!
Final prototype installed
Final prototype installed
Final prototype installed
Final prototype installed
Release Details
Now that all our data are complete, we are fully prepared to release this product. Keep an eye on this thread, as we intend to release our kit within the next 1-2 weeks.
A big thank you to everyone who followed our progress in the development of this product!
Feel free to follow up with any questions!
-John
http://engineering.mishimoto.com/category/ford-mustang-2-3l-ecoboost-performance-air-intake-2015/
The EcoBoost Intake Project, Part 4: Testing Data & Final Product
Mishimoto intake installed
After wrapping up the design of our intake for the 2015, it was time to put the car on the rollers to see if we were making any power gains. As mentioned earlier in this series, we believed that significant power gains were unlikely due to the MAP-based ECU, which is not normally affected by modified intake systems.
Dyno Testing
With that in mind, we strapped the Mustang down and made a few pulls.
2015 Mustang EcoBoost on the dynamometer
[ame]
Testing Results
After making several pulls with both the stock intake and Mishimoto intake, we averaged the runs, and the results are shown in the plot below.
Dyno results for Mishimoto and stock intakes
Although we were a bit skeptical about power gains for this vehicle, we did end up with some nice increases throughout most of the RPM range. These gains are likely due to the reduced restriction caused by the stock airbox system. We saw 4–8 whp gains from about 3,500 rpm through redline. Torque benefits were similar and peaked around 9 wtq at 5,500 rpm.
It is extremely likely that additional modifications and tuning will provide even greater gains with our intake system, thanks to the free-flowing filter and piping design.
We are very pleased with these results. Not only did the vehicle make some decent power gains, but we also really liked the improved tone provided by the intake setup. Spool noise is greatly amplified and sounds terrific both inside and outside of the vehicle.
Filter Surface Area
Along with dyno pulls, we performed some comparison analyses of the stock air filter versus the Mishimoto unit we would be using with our kit.
Comparison of air filter surface areas
Air filter surface area is one of the features we like to compare when looking at the stock intake system. So what is the benefit of greater surface area? Greater filter surface area significantly increases the potential CFM of our filter. More air passages will provide less restrictions, especially for modified vehicles moving more air than a stock vehicle.
Silicone Inlet Hose
Another interesting update for this project is the arrival of our final prototype for the silicone inlet hose. We have been discussing this part for quite some time, and we have posted some 3D-printed prototype images. Check out this unit in its final form!
Mishimoto silicone inlet hose
Mishimoto silicone inlet hose
The next image shows a more detailed shot of our CNC-machined fittings that are molded into the hose.
Mishimoto silicone inlet hose with CNC-machined fittings
The final shot shows the thickness of this hose and the fibers that are embedded with the silicone we use to manufacture this piece.
Mishimoto silicone inlet hose thickness
Intake Piping
Along with our finalized silicone piece, our intake piping was also completed. Check out a few shots.
Final prototype of intake piping
Final prototype of intake piping
Final prototype of intake piping
A few details about this pipe. This unit is constructed from mandrel-bent aluminum, and it features smooth bends to route air from our airbox to the turbocharger inlet. We utilize a bracket to stabilize the pipe and prevent vibration. The bung mounted to the top of the pipe mates perfectly with the stock sensor for the intake air temperature (IAT).
Not a fan of the polished look? Don’t worry, we will be offering this piping in a wrinkle black finish as well. We are also considering a blue (Ford) finish of some sort, so let us know if this interests you and perhaps we can give it a run!
We finish off the end of this piping with our Mishimoto oiled air filter.
Mishimoto air filter
Completed Airbox
The airbox is a key component that helps reduce the effect of engine bay heat on our filter and on air temperatures. You saw our 3D-printed unit earlier; check out the final design below.
Final prototype of intake box
Final prototype of intake box
We also created an easily removable lid for servicing of the filter.
Final prototype of intake box
This box is constructed from powder-coated steel and works to properly isolate the air filter. This unit mounts to existing points within the engine bay and provides a stock-like appearance.
Fully Installed Kit
And check out this kit fully installed in our EB!
Final prototype installed
Final prototype installed
Final prototype installed
Final prototype installed
Release Details
Now that all our data are complete, we are fully prepared to release this product. Keep an eye on this thread, as we intend to release our kit within the next 1-2 weeks.
A big thank you to everyone who followed our progress in the development of this product!
Feel free to follow up with any questions!
-John
l2frankie
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the final product looks nice. would like to see another video of how it sounds outside revving
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