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Beat The Heat! Mishimoto Intercooler R&D!
- Thread starter mishimoto1
- Start date
Thread Starter
#86
Thanks!
Noted!
Thanks for the input. I can confirm we will have a cooler with a black finish, this is one of our common options. In the past we've used a white "M" on the center of the core, but our more recent cooler designs are void of any core branding. We prefer more subtle branding on end tanks, usually in the form of a cast "M". I will pass on this requested color scheme to our team.
Thanks
-John
Noted!
Thanks for the input. I can confirm we will have a cooler with a black finish, this is one of our common options. In the past we've used a white "M" on the center of the core, but our more recent cooler designs are void of any core branding. We prefer more subtle branding on end tanks, usually in the form of a cast "M". I will pass on this requested color scheme to our team.
Thanks
-John
Thread Starter
#87
Quick update!
Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 5: Second Prototype Fabrication
Our quest for the perfect intercooler core continues! So far we’ve perfected the fitment and size of our intercooler core. Our final task is to adjust internal fin composition to create a perfect blend of pressure retention and temperature benefits.
Prototype Ford Fiesta ST Intercooler Fabrication
Timing is a bit of a concern for us at this time. This project has been lengthy, but it will be worth the effort and time when we know our best efforts have been captured in our final product.
Our final version of this intercooler will likely feature a tube-and-fin core. The benefits of weight and airflow are too important to ignore, not to mention the temperature drops we are seeing with a strategically designed internal core.
For our team, the creation of a bar-and-plate cooler is a much quicker process. We’ve found that pressure drop between the two core types is similar if fin style, density, or both are the same. So for this test, we are using two bar-and-plate cores to determine our final fin design that will produce improved internal airflow.
Check out our two cores!
Mishimoto prototype Ford Fiesta ST intercooler cores
Both cores are less dense than the previously tested units, so they should produce a lower pressure drop. They also utilize different fin styles. Check out the internal structures below.
Mishimoto prototype Ford Fiesta ST intercooler cores
The core on the left has a loose fin composition and uses standard straight fins. The core on the right uses offset fins, meaning the rows are offset to provide greater contact surface area. Offset fins also result in a slightly higher restriction.
To conduct testing for these cores, we needed to attach our end tanks. With time constraints in place, we decided to use the end tanks from our rejected prototypes.
Mishimoto prototype Ford Fiesta ST intercooler core fabrication
Once separated, the powder coat was removed so we had a clean surface for welding.
Mishimoto Fiesta ST performance parts fabrication
Mishimoto Fiesta ST performance parts fabrication
Our talented fabrication team then laid down some impressive welds to finish the prototype fabrication.
Mishimoto Fiesta ST performance parts fabrication
Coming Up – Additional Testing
Next time we will be testing these two new prototype intercoolers on our Fiesta. Based on the data we collect; we should be able to start producing our first batch of coolers soon.
Keep an eye on our blog for additional updates on upcoming Fiesta ST performance parts.
Thanks for reading!
-John
Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 5: Second Prototype Fabrication
Our quest for the perfect intercooler core continues! So far we’ve perfected the fitment and size of our intercooler core. Our final task is to adjust internal fin composition to create a perfect blend of pressure retention and temperature benefits.
Prototype Ford Fiesta ST Intercooler Fabrication
Timing is a bit of a concern for us at this time. This project has been lengthy, but it will be worth the effort and time when we know our best efforts have been captured in our final product.
Our final version of this intercooler will likely feature a tube-and-fin core. The benefits of weight and airflow are too important to ignore, not to mention the temperature drops we are seeing with a strategically designed internal core.
For our team, the creation of a bar-and-plate cooler is a much quicker process. We’ve found that pressure drop between the two core types is similar if fin style, density, or both are the same. So for this test, we are using two bar-and-plate cores to determine our final fin design that will produce improved internal airflow.
Check out our two cores!
Mishimoto prototype Ford Fiesta ST intercooler cores
Both cores are less dense than the previously tested units, so they should produce a lower pressure drop. They also utilize different fin styles. Check out the internal structures below.
Mishimoto prototype Ford Fiesta ST intercooler cores
The core on the left has a loose fin composition and uses standard straight fins. The core on the right uses offset fins, meaning the rows are offset to provide greater contact surface area. Offset fins also result in a slightly higher restriction.
To conduct testing for these cores, we needed to attach our end tanks. With time constraints in place, we decided to use the end tanks from our rejected prototypes.
Mishimoto prototype Ford Fiesta ST intercooler core fabrication
Once separated, the powder coat was removed so we had a clean surface for welding.
Mishimoto Fiesta ST performance parts fabrication
Mishimoto Fiesta ST performance parts fabrication
Our talented fabrication team then laid down some impressive welds to finish the prototype fabrication.
Mishimoto Fiesta ST performance parts fabrication
Coming Up – Additional Testing
Next time we will be testing these two new prototype intercoolers on our Fiesta. Based on the data we collect; we should be able to start producing our first batch of coolers soon.
Keep an eye on our blog for additional updates on upcoming Fiesta ST performance parts.
Thanks for reading!
-John
Thread Starter
#90
Sorry guys. Things have been a bit hectic in the shop lately but we are definitely moving along. Data crunch is complete and I should have a post together early next week. We've finalized our core design and have started producing our first batch of units.
Thanks
-John
Thanks
-John
![[rockon]](/images/smilies/icon_smile_headbang.gif "Rock On [rockon]"){kind=icon}
![[neener]](/images/smilies/icon_smile_neener.gif "Neener [neener]"){kind=icon}
Thread Starter
#95
Final update before our pre-sale!
Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 6: Prototype Testing Round 2
We are narrowing down our selection of core designs through both extensive research and some pretty neat testing processes. After seeing some impressive heat transfer numbers on our first round of Ford Fiesta ST intercooler testing, we decided to focus on producing a better balance between pressure drop and reduction of intake temperatures.
New prototypes were constructed, and we were ready to make some dyno runs.
Testing Fiesta ST performance parts
Testing Fiesta ST performance parts
These dyno runs included two prototype cores, which were compared to the stock intercooler. Although both cores are of the bar-and-plate style, we intend to use this data to finalize our tube-and-fin intercooler. We saw higher pressure drops with our previous round of testing, so with this testing, we hope to determine the optimal core density that will provide an ideal compromise between pressure drop and heat transfer.
Pressure Drop Data
First, let’s take a look at the pressure drop numbers from each of the cores we tested during the development of this cooler.
Testing Fiesta ST performance parts
This plot is a bit much to take in at once. Below is a quick chart showing the average pressure drop for each cooler we tested.
As you can see, prototypes from our first round of testing showed far too much pressure drop. Although this translated into massive temperature drops, we wanted to see if we could provide a better blend. Our second set of prototype cores showed much more promising pressure drop data that hovered right around the average of the stock cooler.
Temperature Data
The data collected above show very promising pressure drop numbers from our third and fourth prototype cores. As long as these coolers provide improved cooling benefits, we can consider them for our final core selections. Let’s jump right to the temperature data.
Ford Fiesta ST intercooler testing data
The chart above clearly depicts a serious difference in cooling ability between the tested cores. The stock unit performed worst among the three cores. The fourth prototype core improved slightly over stock, while the third prototype design showed very impressive heat rejection.
The data above are summarized in the chart below.
One of the key columns of this chart shows the rise in outlet temperatures. Our fourth prototype is a slight improvement over stock; however, the third prototype is essentially unaffected by the pull. We see barely any temperature change during the test.
Can you guess which core we selected?
Our third prototype provides a 20-degree drop in outlet temperatures while resulting in only a 0.2 psi difference in average pressure drop during a pull. This prototype will be a tube-and-fin cooler in its final design. It will be a lightweight cooler that still allows ample airflow to the radiator for engine cooling.
Coming Up – Ford Fiesta ST Intercooler Discounted Pre-sale
It is time to get these intercoolers into the hands of customers for independent testing. Our team has started producing the first batch of units, and we will be launching a discounted pre-sale for forum members. Check back soon for details regarding pricing information and shipment dates.
Thanks for reading. Feel free to follow-up with any questions!
Keep an eye on our blog for more updates on upcoming Fiesta ST performance parts.
-John
Beat The Heat! Mishimoto Fiesta ST Intercooler R&D, Part 6: Prototype Testing Round 2
We are narrowing down our selection of core designs through both extensive research and some pretty neat testing processes. After seeing some impressive heat transfer numbers on our first round of Ford Fiesta ST intercooler testing, we decided to focus on producing a better balance between pressure drop and reduction of intake temperatures.
New prototypes were constructed, and we were ready to make some dyno runs.
Testing Fiesta ST performance parts
Testing Fiesta ST performance parts
These dyno runs included two prototype cores, which were compared to the stock intercooler. Although both cores are of the bar-and-plate style, we intend to use this data to finalize our tube-and-fin intercooler. We saw higher pressure drops with our previous round of testing, so with this testing, we hope to determine the optimal core density that will provide an ideal compromise between pressure drop and heat transfer.
Pressure Drop Data
First, let’s take a look at the pressure drop numbers from each of the cores we tested during the development of this cooler.
Testing Fiesta ST performance parts
This plot is a bit much to take in at once. Below is a quick chart showing the average pressure drop for each cooler we tested.
As you can see, prototypes from our first round of testing showed far too much pressure drop. Although this translated into massive temperature drops, we wanted to see if we could provide a better blend. Our second set of prototype cores showed much more promising pressure drop data that hovered right around the average of the stock cooler.
Temperature Data
The data collected above show very promising pressure drop numbers from our third and fourth prototype cores. As long as these coolers provide improved cooling benefits, we can consider them for our final core selections. Let’s jump right to the temperature data.
Ford Fiesta ST intercooler testing data
The chart above clearly depicts a serious difference in cooling ability between the tested cores. The stock unit performed worst among the three cores. The fourth prototype core improved slightly over stock, while the third prototype design showed very impressive heat rejection.
The data above are summarized in the chart below.
One of the key columns of this chart shows the rise in outlet temperatures. Our fourth prototype is a slight improvement over stock; however, the third prototype is essentially unaffected by the pull. We see barely any temperature change during the test.
Can you guess which core we selected?
Our third prototype provides a 20-degree drop in outlet temperatures while resulting in only a 0.2 psi difference in average pressure drop during a pull. This prototype will be a tube-and-fin cooler in its final design. It will be a lightweight cooler that still allows ample airflow to the radiator for engine cooling.
Coming Up – Ford Fiesta ST Intercooler Discounted Pre-sale
It is time to get these intercoolers into the hands of customers for independent testing. Our team has started producing the first batch of units, and we will be launching a discounted pre-sale for forum members. Check back soon for details regarding pricing information and shipment dates.
Thanks for reading. Feel free to follow-up with any questions!
Keep an eye on our blog for more updates on upcoming Fiesta ST performance parts.
-John
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