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Fresh Air for the Fiesta! ST Performance Intake R&D!
- Thread starter mishimoto1
- Start date
Thread Starter
#62
Thanks for the kind words!
Thanks for linking that koozy! Ran out of time on Friday and did not have time to get the post up here on the forum. Details on our testing can be found below!
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 5: Prototype Dyno Testing
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 with testing is to procure sound clips with our Ford Fiesta ST intake installed. When replacing the restrictive stock setup, intake volume is typically increased, which can be a great added bonus for aftermarket intake installation.
No more waiting, check out the video!
https://www.youtube.com/watch?v=_kjqtbyTz4g
First impressions, this intake sounds fantastic. Noise from the bypass valve is far more audible with our setup installed. Turbo spool sounds are also increased, but not to the point of annoyance. If I was a FIST owner, this would be the blend I?d want for sound improvements.
Next, let?s take a look at the dyno plot we produced with back-to-back testing of the stock Fiesta intake and our prototype.
Ford Fiesta ST intake dyno plot comparison
One thing to keep in mind regarding our testing. Each plot shown is an average of three runs from each setup. We made pulls until the car produced three consistent plots, which were then averaged. To be clear, we did not compare a low run from the stock Ford Fiesta ST intake to a high run from our setup, so this data is completely repeatable.
Our pull starts at 2500 rpm and ends at around 6300 rpm. As you can see, the Mishimoto intake made gains throughout most of the power band, to the tune of around 1-3 whp/wtq on average. Maximum gains of 6 whp and 10 wtq were recorded early on in the pull, at just over 3,000 rpm. Pretty good results, especially considering we did not anticipate huge gains.
As we?ve noted, reduced restriction is the primary contributor to these gains. Our filter has a lot to do with this, made evident by the surface area comparison below.
Ford Fiesta ST filter surface area comparison
The stock filter is rather small and we were able to easily improve the size of the filtration area.
Coming Up!
Last series we discussed checking out both intake temperatures as well as the functionality of our additional port on the airbox. The port proved to make negligible differences on the dyno, but we are still interested in seeing if it can contribute to bringing cold air into the box. We will be conducting some additional testing to determine if any changes are needed with our Fiesta ST intake prototype design!
Keep an eye out for more blog updates on new Mishimoto Fiesta ST parts!
Thanks for reading!
-John
Thanks for linking that koozy! Ran out of time on Friday and did not have time to get the post up here on the forum. Details on our testing can be found below!
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 5: Prototype Dyno Testing
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 with testing is to procure sound clips with our Ford Fiesta ST intake installed. When replacing the restrictive stock setup, intake volume is typically increased, which can be a great added bonus for aftermarket intake installation.
No more waiting, check out the video!
https://www.youtube.com/watch?v=_kjqtbyTz4g
First impressions, this intake sounds fantastic. Noise from the bypass valve is far more audible with our setup installed. Turbo spool sounds are also increased, but not to the point of annoyance. If I was a FIST owner, this would be the blend I?d want for sound improvements.
Next, let?s take a look at the dyno plot we produced with back-to-back testing of the stock Fiesta intake and our prototype.
Ford Fiesta ST intake dyno plot comparison
One thing to keep in mind regarding our testing. Each plot shown is an average of three runs from each setup. We made pulls until the car produced three consistent plots, which were then averaged. To be clear, we did not compare a low run from the stock Ford Fiesta ST intake to a high run from our setup, so this data is completely repeatable.
Our pull starts at 2500 rpm and ends at around 6300 rpm. As you can see, the Mishimoto intake made gains throughout most of the power band, to the tune of around 1-3 whp/wtq on average. Maximum gains of 6 whp and 10 wtq were recorded early on in the pull, at just over 3,000 rpm. Pretty good results, especially considering we did not anticipate huge gains.
As we?ve noted, reduced restriction is the primary contributor to these gains. Our filter has a lot to do with this, made evident by the surface area comparison below.
Ford Fiesta ST filter surface area comparison
The stock filter is rather small and we were able to easily improve the size of the filtration area.
Coming Up!
Last series we discussed checking out both intake temperatures as well as the functionality of our additional port on the airbox. The port proved to make negligible differences on the dyno, but we are still interested in seeing if it can contribute to bringing cold air into the box. We will be conducting some additional testing to determine if any changes are needed with our Fiesta ST intake prototype design!
Keep an eye out for more blog updates on new Mishimoto Fiesta ST parts!
Thanks for reading!
-John
Thread Starter
#67
Yes, our preliminary data has shown similar information. More on that coming in our next project update. Thanks for the input.
We are working on this project as quickly as possible without impacting the end product. Yes, we'd like to release this intake system yesterday, but we also want this product to be a very high quality kit. We will have another update next week!
Thanks for sticking with us!
-John
We are working on this project as quickly as possible without impacting the end product. Yes, we'd like to release this intake system yesterday, but we also want this product to be a very high quality kit. We will have another update next week!
Thanks for sticking with us!
-John
Thread Starter
#73
Thanks!
Correct! The airbox is in place to isolate the filter from the warm engine bay. In similar intake projects with other turbocharged vehicles, we have recorded data showing lower intake temperatures with the use of an airbox as opposed to an open filter. The airbox also helps direct and contain the incoming airflow to the filter.
-John
Correct! The airbox is in place to isolate the filter from the warm engine bay. In similar intake projects with other turbocharged vehicles, we have recorded data showing lower intake temperatures with the use of an airbox as opposed to an open filter. The airbox also helps direct and contain the incoming airflow to the filter.
-John
Thread Starter
#75
Thanks for taking a look Spinman! Unfortunately our intake pipe follows a different route compared to the induction hose which fits the stock intake. This means we are unable to test the silicone piece with our full intake kit. My assumption is that gains would be identical with or without silicone in this section. The inner diameter of this section is the same between both pieces, so flow should be relatively similar. From looking at our results of the induction hose tests, we can infer that most of the power achieved with our full intake is due to replacing the restrictive stock piping. The additional bump in power is likely a result of the higher flow filter and airbox setup our full intake includes.
For further clarification, details on both setups can be found below.
Option 1: Silicone Induction Hose
• Easy To Install
• Retains Factory Airbox
• 5whp / 10 wtq bolt-on gains
• Factory-Like Appearance
• Inexpensive (Now on Pre-sale, $149.95)
• No additional intake noise
Our induction hose is quite an interesting piece. This component replaces the factory rubber induction hose which features accordion portions to allow for engine flex. As a result, these portions of the hose cause restrictions to airflow. Smoothening the internal diameter of the hose proved to make a massive impact on power output, even our engineering team was a bit surprised. Dyno plot shown below!
Power is made through the low end through 5,500 rpm. Once at the top of the power band, power output is similar to the stock hose. Maximum gains are seen around 3,000 rpm to the tune of 5 whp and 10 wtq, which is where the factory plot seems to dip while our induction hose retains a smoother line. Through most of the band, we are seeing 1-3 whp/wtq which is a nice increase considering you can bolt this on in around 15 minutes (this includes beer breaks).
For more information about our R&D, as well as an evaluation of the stock hose, check out the thread below.
http://www.fiestastforum.com/forum/...sta-ST-Silicone-Induction-Hose-R-amp-D-Report
Option 2: Full Intake System
Prototype Image
• Slightly longer installation process
• Replaces factory airbox
• 6 whp / 10 wtq bolt-on gains (More Power In Top End)
• Bolder Engine Bay Addition
• Increased Intake Volume, Improved Induction Noise
Our intake system is still in the development phase and is for a bit of a different customer. Your first question may be in regards to power output. Why is it only making one more whp? Take a look at our plot for this system.
The plot is strikingly similar to that of our induction hose. Primary differences are the power gains at the top end, which we can attribute to the removal of the restrictive stock airbox. On average, this system provides an additional 1-2 whp / wtq over the induction hose through most of the powerband. Not huge, but every pony counts.
This setup is for someone looking for both noise and power, and it certainly provides both. This airbox is much less subtle than our induction hose. You can hear it and you can certainly see it when the hood is open. We are wrapping up development here within the next few weeks and will likely launch a discounted pre-sale.
For full details on the R&D process, check out our thread below.
http://www.fiestastforum.com/forum/...for-the-Fiesta!-ST-Performance-Intake-R-amp-D!
That should provide some basic insight into the results we saw with the components designed by our team. Both are great products and nice additions to the ST. Let us know if we can answer any questions about either component.
Thanks
-John
For further clarification, details on both setups can be found below.
Option 1: Silicone Induction Hose
• Easy To Install
• Retains Factory Airbox
• 5whp / 10 wtq bolt-on gains
• Factory-Like Appearance
• Inexpensive (Now on Pre-sale, $149.95)
• No additional intake noise
Our induction hose is quite an interesting piece. This component replaces the factory rubber induction hose which features accordion portions to allow for engine flex. As a result, these portions of the hose cause restrictions to airflow. Smoothening the internal diameter of the hose proved to make a massive impact on power output, even our engineering team was a bit surprised. Dyno plot shown below!
Power is made through the low end through 5,500 rpm. Once at the top of the power band, power output is similar to the stock hose. Maximum gains are seen around 3,000 rpm to the tune of 5 whp and 10 wtq, which is where the factory plot seems to dip while our induction hose retains a smoother line. Through most of the band, we are seeing 1-3 whp/wtq which is a nice increase considering you can bolt this on in around 15 minutes (this includes beer breaks).
For more information about our R&D, as well as an evaluation of the stock hose, check out the thread below.
http://www.fiestastforum.com/forum/...sta-ST-Silicone-Induction-Hose-R-amp-D-Report
Option 2: Full Intake System
Prototype Image
• Slightly longer installation process
• Replaces factory airbox
• 6 whp / 10 wtq bolt-on gains (More Power In Top End)
• Bolder Engine Bay Addition
• Increased Intake Volume, Improved Induction Noise
Our intake system is still in the development phase and is for a bit of a different customer. Your first question may be in regards to power output. Why is it only making one more whp? Take a look at our plot for this system.
The plot is strikingly similar to that of our induction hose. Primary differences are the power gains at the top end, which we can attribute to the removal of the restrictive stock airbox. On average, this system provides an additional 1-2 whp / wtq over the induction hose through most of the powerband. Not huge, but every pony counts.
This setup is for someone looking for both noise and power, and it certainly provides both. This airbox is much less subtle than our induction hose. You can hear it and you can certainly see it when the hood is open. We are wrapping up development here within the next few weeks and will likely launch a discounted pre-sale.
For full details on the R&D process, check out our thread below.
http://www.fiestastforum.com/forum/...for-the-Fiesta!-ST-Performance-Intake-R-amp-D!
That should provide some basic insight into the results we saw with the components designed by our team. Both are great products and nice additions to the ST. Let us know if we can answer any questions about either component.
Thanks
-John
Thread Starter
#76
Time for an awesome update!
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype
We are quite excited about the completion of our final prototype intake for the Ford Fiesta ST (FIST)! After months of development, testing, and design work, we are ready to present our final creation. First we will go through each component and cover important details regarding their features.
Silicone Turbo Inlet Hose
Starting at the turbocharger compressor inlet, we have our silicone inlet hose. This piece was constructed specifically for this kit and is extremely robust.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Five layers of silicone comprise this hose, along with embedded fibers and steel wire for added rigidity. This hose must withstand the suction created by the turbocharger, which is why additional materials are embedded for added strength.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Along with suction, this hose will also see relatively high temperatures. Silicone in this five-ply formula will have no issues providing years of reliable performance.
Aluminum Intake Pipe
Next along the air intake route is our aluminum piping.
Mishimoto’s Fiesta ST aluminum intake pipe
This pipe features smooth mandrel bends to route intake air from the airbox to the turbo inlet hose. Distinguishable features include the MAF (mass airflow) housing, two CCV (crankcase control valve) line ports, and a mounting bracket.
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Each of these components assists in making our end product a full bolt-on intake solution.
Airbox and Filter
One of the most interesting components in this kit is the airbox. This portion of the system directs airflow from the stock front scoop to the air filter contained within the box.
Mishimoto’s Fiesta ST intake airbox
This image shows the intake’s pipe entry point as well as the portion of the box that attaches to the stock air scoop. This airbox was shaped specifically to fit within the constraints of the very confined FIST engine bay. The top of this airbox features rivet nuts to attach the lid.
Mishimoto’s Fiesta ST intake airbox lid
Mishimoto’s Fiesta ST intake airbox
Looking at the base of the airbox reveals our two mounting pegs. These are designed to emulate the stock airbox mounting pegs, and they should drop into place perfectly.
Check out a look at the box with the lid installed!
Mishimoto’s Fiesta ST airbox with lid
This kit will utilize our oiled air filter, which provides impressive filter surface area yet still manages to fit within the confines of this tiny engine bay.
Our filters are completely serviceable, meaning they can be cleaned and re-oiled for a lifetime of repeated use.
Coming Up – Installed Images
Full Fiesta intake kit
We have one final test fit to conduct before starting the manufacturing of our first batch of intake kits. Once this prototype is installed, we will snap a few pictures and post them for your enjoyment.
Thanks for reading!
-John
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype
We are quite excited about the completion of our final prototype intake for the Ford Fiesta ST (FIST)! After months of development, testing, and design work, we are ready to present our final creation. First we will go through each component and cover important details regarding their features.
Silicone Turbo Inlet Hose
Starting at the turbocharger compressor inlet, we have our silicone inlet hose. This piece was constructed specifically for this kit and is extremely robust.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Five layers of silicone comprise this hose, along with embedded fibers and steel wire for added rigidity. This hose must withstand the suction created by the turbocharger, which is why additional materials are embedded for added strength.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Along with suction, this hose will also see relatively high temperatures. Silicone in this five-ply formula will have no issues providing years of reliable performance.
Aluminum Intake Pipe
Next along the air intake route is our aluminum piping.
Mishimoto’s Fiesta ST aluminum intake pipe
This pipe features smooth mandrel bends to route intake air from the airbox to the turbo inlet hose. Distinguishable features include the MAF (mass airflow) housing, two CCV (crankcase control valve) line ports, and a mounting bracket.
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Each of these components assists in making our end product a full bolt-on intake solution.
Airbox and Filter
One of the most interesting components in this kit is the airbox. This portion of the system directs airflow from the stock front scoop to the air filter contained within the box.
Mishimoto’s Fiesta ST intake airbox
This image shows the intake’s pipe entry point as well as the portion of the box that attaches to the stock air scoop. This airbox was shaped specifically to fit within the constraints of the very confined FIST engine bay. The top of this airbox features rivet nuts to attach the lid.
Mishimoto’s Fiesta ST intake airbox lid
Mishimoto’s Fiesta ST intake airbox
Looking at the base of the airbox reveals our two mounting pegs. These are designed to emulate the stock airbox mounting pegs, and they should drop into place perfectly.
Check out a look at the box with the lid installed!
Mishimoto’s Fiesta ST airbox with lid
This kit will utilize our oiled air filter, which provides impressive filter surface area yet still manages to fit within the confines of this tiny engine bay.
Our filters are completely serviceable, meaning they can be cleaned and re-oiled for a lifetime of repeated use.
Coming Up – Installed Images
Full Fiesta intake kit
We have one final test fit to conduct before starting the manufacturing of our first batch of intake kits. Once this prototype is installed, we will snap a few pictures and post them for your enjoyment.
Thanks for reading!
-John
Looks great. Just curious though, what is the thought process behind doing the R&D and creating a brand new product, yet not making it compatible with the latest model year too? I can understand it being an issue for companies that finalized their design a few years back and now have a ton of stock already made. It just seems like you guys are at the point now where you can remedy this and make it work with the 2016 models.
Hey John, a couple questions what material is the air box made out of and was there any consideration of using plastic instead of aluminum for the intake piping? Correct me if I'm wrong but isn't' plastics less susceptible to heatstroke compared to aluminum?
Time for an awesome update!
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype
We are quite excited about the completion of our final prototype intake for the Ford Fiesta ST (FIST)! After months of development, testing, and design work, we are ready to present our final creation. First we will go through each component and cover important details regarding their features.
Silicone Turbo Inlet Hose
Starting at the turbocharger compressor inlet, we have our silicone inlet hose. This piece was constructed specifically for this kit and is extremely robust.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Five layers of silicone comprise this hose, along with embedded fibers and steel wire for added rigidity. This hose must withstand the suction created by the turbocharger, which is why additional materials are embedded for added strength.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Along with suction, this hose will also see relatively high temperatures. Silicone in this five-ply formula will have no issues providing years of reliable performance.
Aluminum Intake Pipe
Next along the air intake route is our aluminum piping.
Mishimoto’s Fiesta ST aluminum intake pipe
This pipe features smooth mandrel bends to route intake air from the airbox to the turbo inlet hose. Distinguishable features include the MAF (mass airflow) housing, two CCV (crankcase control valve) line ports, and a mounting bracket.
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Each of these components assists in making our end product a full bolt-on intake solution.
Airbox and Filter
One of the most interesting components in this kit is the airbox. This portion of the system directs airflow from the stock front scoop to the air filter contained within the box.
Mishimoto’s Fiesta ST intake airbox
This image shows the intake’s pipe entry point as well as the portion of the box that attaches to the stock air scoop. This airbox was shaped specifically to fit within the constraints of the very confined FIST engine bay. The top of this airbox features rivet nuts to attach the lid.
Mishimoto’s Fiesta ST intake airbox lid
Mishimoto’s Fiesta ST intake airbox
Looking at the base of the airbox reveals our two mounting pegs. These are designed to emulate the stock airbox mounting pegs, and they should drop into place perfectly.
Check out a look at the box with the lid installed!
Mishimoto’s Fiesta ST airbox with lid
This kit will utilize our oiled air filter, which provides impressive filter surface area yet still manages to fit within the confines of this tiny engine bay.
Our filters are completely serviceable, meaning they can be cleaned and re-oiled for a lifetime of repeated use.
Coming Up – Installed Images
Full Fiesta intake kit
We have one final test fit to conduct before starting the manufacturing of our first batch of intake kits. Once this prototype is installed, we will snap a few pictures and post them for your enjoyment.
Thanks for reading!
-John
Fresh Air For The Fiesta! ST Performance Intake R&D, Part 6: Final Prototype
We are quite excited about the completion of our final prototype intake for the Ford Fiesta ST (FIST)! After months of development, testing, and design work, we are ready to present our final creation. First we will go through each component and cover important details regarding their features.
Silicone Turbo Inlet Hose
Starting at the turbocharger compressor inlet, we have our silicone inlet hose. This piece was constructed specifically for this kit and is extremely robust.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Five layers of silicone comprise this hose, along with embedded fibers and steel wire for added rigidity. This hose must withstand the suction created by the turbocharger, which is why additional materials are embedded for added strength.
Mishimoto’s Ford Fiesta ST intake silicone inlet hose
Along with suction, this hose will also see relatively high temperatures. Silicone in this five-ply formula will have no issues providing years of reliable performance.
Aluminum Intake Pipe
Next along the air intake route is our aluminum piping.
Mishimoto’s Fiesta ST aluminum intake pipe
This pipe features smooth mandrel bends to route intake air from the airbox to the turbo inlet hose. Distinguishable features include the MAF (mass airflow) housing, two CCV (crankcase control valve) line ports, and a mounting bracket.
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Mishimoto’s Fiesta ST aluminum intake pipe
Each of these components assists in making our end product a full bolt-on intake solution.
Airbox and Filter
One of the most interesting components in this kit is the airbox. This portion of the system directs airflow from the stock front scoop to the air filter contained within the box.
Mishimoto’s Fiesta ST intake airbox
This image shows the intake’s pipe entry point as well as the portion of the box that attaches to the stock air scoop. This airbox was shaped specifically to fit within the constraints of the very confined FIST engine bay. The top of this airbox features rivet nuts to attach the lid.
Mishimoto’s Fiesta ST intake airbox lid
Mishimoto’s Fiesta ST intake airbox
Looking at the base of the airbox reveals our two mounting pegs. These are designed to emulate the stock airbox mounting pegs, and they should drop into place perfectly.
Check out a look at the box with the lid installed!
Mishimoto’s Fiesta ST airbox with lid
This kit will utilize our oiled air filter, which provides impressive filter surface area yet still manages to fit within the confines of this tiny engine bay.
Our filters are completely serviceable, meaning they can be cleaned and re-oiled for a lifetime of repeated use.
Coming Up – Installed Images
Full Fiesta intake kit
We have one final test fit to conduct before starting the manufacturing of our first batch of intake kits. Once this prototype is installed, we will snap a few pictures and post them for your enjoyment.
Thanks for reading!
-John
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