Page 13 - ford

We've discussed R&D for many of our typical product segments for the Fiesta ST. These include our in-progress aluminum radiator, our already released catch can kit and oil cooler solution, as well as our nearly complete intake system and exhaust components (both cat-back and downpipe). Our company is also known for its strong line of heat exchangers, so we certainly need to see what can be done about the undersized stock intercooler on the Fiesta.

Heat is a big enemy of the Fiesta, as many have already discovered during track driving. High oil temperatures, high coolant temperatures, and a heat-soaked intercooler all commonly occur after short periods of aggressive driving. We've been actively tackling both the coolant and oil temperature concerns in other development threads, but now it's time to lower the intake temperatures with an upgraded intercooler.

Stock Intercooler Evaluation

You've probably seen the stock Ford Fiesta ST intercooler on

In our last post we took a good look at the stock Fiesta ST exhaust and the initial design of our cat-back exhaust. The exhaust was fabricated and installed on the car and then it was time to test the stock system.

To Resonate or Not to Resonate

Getting the sound just right was quite a process. Our initial prototype featured 2.5" piping with a single rear muffler. This design did not feature a resonated mid-pipe unlike the stock unit. The initial design was sound tested on the dyno and also test driven by several members of the team. While we loved the low growl of the exhaust as it was, we wanted to test a resonated version before settling on a final design. As with all exhaust development projects, we are aiming for a final product that sounds great on throttle while still being

With just a couple small tasks to go, we're near the completion of this 2015 Mustang cat-back exhaust project. Our design for this system is complete from the downpipe connection to the end of the stainless exhaust tips.

3D Models

Our prototype exhaust meets our requirements for both fitment and performance, so it was time to create a 3D-model of our design, which would ensure that our manufactured exhausts match our design exactly. After some time at the computer screen working in Solidworks, we ended up with the awesome renderings below!

Mishimoto 2015 Mustang EcoBoost exhaust rendering

Dyno preparation for Fiesta ST parts testing

Testing day has finally arrived and it's time to see how our new Fiesta ST parts perform! After weeks of prototype design and fabrication, we have our first prototype Ford Fiesta ST intake system ready for dyno testing. Our first round of product testing is being conducted for two reasons:

First, we want to evaluate power output. Our initial post explained that we were skeptical about making power with our intake. The Fiesta is a MAP-based vehicle and only uses its MAF sensor to gather temperature data. Through our years of development, extracting additional power from speed density (MAP-calculated) is a bit of a challenge. The gains we usually see on these vehicles is a result of reduced restriction within the intake tract. With this intake we've certainly improved flow, so let's see what we are able to produce.

Our second goal

Introduction and the Stock Downpipe

Another addition to the Fiesta ST collection! Our Fiesta build is coming along nicely, and I am happy to announce some progress on our downpipe project. As with any R&D undertaking the first step is to take a look at the stock setup and see how it can be improved.

Stock Fiesta ST downpipe

Although Ford has a pretty nice design, we are planning to make it a bit better by increasing the diameter of the downpipe to 3" throughout. As opposed to the stock unit which features 3" pipe only where the downpipe meets the turbo. In order to achieve excellent fitment with the turbo, we will keep the flange as similar to stock as possible. To collect the most accurate measurements

We're getting closer to dyno testing! Our intake piping and turbo inlet hose are now complete. A well-designed airbox is the last portion of our intake design before we begin performance testing. The airbox will provide a shield for the filter to reduce the impact of engine bay heat. It also allows us to create a volume for cold air to enter from the stock duct, routing directly to our filter.

The airbox design was pretty extensive for this project, so this is a long post. Sit back, crack open your favorite beverage, and read on!

Airbox Fabrication

We started this process with cardboard templates. These templates helped us quickly adjust and modify the shape and bends until we had a design that provided for appropriate clearance. The space between the battery and air duct is quite slender, so the design will need to be precise.

We've logged some miles (and smiles) during the testing of our two cat-back exhaust setups. We've decided on a strategy for the muffler selection, one that we feel best suits the tones of the Mustang EcoBoost (EB). Our team determined that the round muffler setup is just a touch too loud, and that the oval mufflers shown in the previous segment provided the exact sound we are seeking. Months of tedious design and testing have resulted in drone-less operation on the highway, improved volume at wide-open-throttle( WOT), and stock-like sounds during light/partial throttle.

I am sure you guys are eager for some final sound clips, but you will have to wait just a bit longer. In the meantime, we've settled on the muffler tip we will be using, and we've fitted it to our final prototype. Check out the process below!

Tip Design

We've gone with an appealing tip design for our EcoBoost Mustang exhaust system. Check out a few shots prior to mating this with the

This is a pretty cool post, something a bit out of the ordinary for our projects. We typically utilize our existing silicone boots in our intercooler kits, intake systems, etc. For this project, we decided to manufacture the first portion of our intake system from a wire-reinforced silicone hose. This would facilitate an easier installation, and it would also provide a smooth airflow transition from the small turbocharger compressor inlet to our intake's large pipe diameter. Since we like to show you what goes into developing our prototypes, check out the process for creating our silicone turbo inlet hose below!

Printing Our Fixture

The hose we have in mind will follow the path of the stock induction hose, which is actually a plastic piece on the stock ST. Before beginning our silicone project, we needed a fixture that would serve as a base for the silicone layers that will be applied. After making a model in Solidworks, we fired up the 3D printer and watched

Now that we had a ton of information and data points for the stock intake system, it was time to begin creating our own design.

Piping Fabrication

We're starting our intake system at the turbocharger and working to the airbox. We intend to place our box in the same location as the stock unit so we can take advantage of the stock cold-air duct.

We switched on the band saw, fired up the welder, and started tackling the route for our prototype pipe. Our first length runs from the turbocharger around to the rear of the valve cover.

Prototype Fiesta ST parts