Mishimoto's Performance Intercooler R&D Thread

[doccoch]

@Mishimoto please give us an update on the high mount option. I've check your website every week without any news. wondering if it's worth waiting or having a shop relocate existing intercooler for me?

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[Mishimoto]

@Mishimoto please give us an update on the high mount option. I've check your website every week without any news. wondering if it's worth waiting or having a shop relocate existing intercooler for me?

The intercoolers are coming! We're still aiming to have a presale early-to-mid first quarter of next year. Right now we're in the process of manufacturing these intercoolers, which is also a waiting game for us as well, mainly because we're stoked to get these on your Broncos!

I'll keep you guys updated as we get closer!

-Nick

 

[Mishimoto]

Hey Guys!

Just bumping this thread up with another dive into the specifics of this kit!

High Road – 2021+ Ford Bronco Performance Intercooler R&D, Part 5 – Production Sample Ducting

When it comes to keeping charged air temperatures in check, the intercooler is only as good as its air source. The core's size and the end tanks' shape almost become irrelevant if no reliable source of fresh air passes through the fins. Intercooling is a team effort, and while the core may be the star of the show, it's nothing without the rest of the crew. In the last post, we covered the literal supporting cast, but now it's time to introduce the ducting.

From the factory, these Broncos roll off the line with a plethora of perfectly sculpted ducting that's purpose-built for force-feeding air straight through the Bronco's intercooler core. The trouble is that the intercooler isn't in that location anymore. So, to keep this stream of air flowing through our new core, we also developed our own ducting to guide this incoming air through the fins properly.

Now, the new location is in a much more direct path of fresh air since it's slid up to join the rest of the cooling stack, but without extra guidance, some of this airflow can skip the intercooler altogether. To prevent this, our engineer, Dan, developed our lower duct to capture this airflow. Attaching to the chassis, this duct extends to the bumper to create this channel. Dan also devised a two-piece design to integrate with the standard or OEM modular bumper.

This configuration is intended for the modular bumper and the foam slots inside the bumper to reduce any road noise. The pop-clips are destined for the standard Bronco bumper. The front section of this duct is removed, and the remainder clips between the bumper and lower grill trim.

Our upper duction is aimed more at maintaining the status quo. Relocating the Bronco's intercooler meant we had to make cuts in the original supporting cast, specifically the grille shutters. The engineers at Ford incorporated additional air ducting in these shutters that keep air flowing through the engine bay and to the intake that we didn't want to compromise. So, we duplicated these ducts to keep things flowing in the right direction.

Airflow is one of the best supporting components to any intercooling system, and we wanted to ensure that our kit keeps the air flowing. So, make sure you stay tuned to see how well the air flows through our kit coming soon!

Keep an eye out towards the end of the month for our dyno results for the 2.7L!

-Nick

 

[brokentwig]

Hey Guys!

Just bumping this thread up with another dive into the specifics of this kit!

High Road – 2021+ Ford Bronco Performance Intercooler R&D, Part 5 – Production Sample Ducting

When it comes to keeping charged air temperatures in check, the intercooler is only as good as its air source. The core's size and the end tanks' shape almost become irrelevant if no reliable source of fresh air passes through the fins. Intercooling is a team effort, and while the core may be the star of the show, it's nothing without the rest of the crew. In the last post, we covered the literal supporting cast, but now it's time to introduce the ducting.

From the factory, these Broncos roll off the line with a plethora of perfectly sculpted ducting that's purpose-built for force-feeding air straight through the Bronco's intercooler core. The trouble is that the intercooler isn't in that location anymore. So, to keep this stream of air flowing through our new core, we also developed our own ducting to guide this incoming air through the fins properly.

Now, the new location is in a much more direct path of fresh air since it's slid up to join the rest of the cooling stack, but without extra guidance, some of this airflow can skip the intercooler altogether. To prevent this, our engineer, Dan, developed our lower duct to capture this airflow. Attaching to the chassis, this duct extends to the bumper to create this channel. Dan also devised a two-piece design to integrate with the standard or OEM modular bumper.

This configuration is intended for the modular bumper and the foam slots inside the bumper to reduce any road noise. The pop-clips are destined for the standard Bronco bumper. The front section of this duct is removed, and the remainder clips between the bumper and lower grill trim.

Our upper duction is aimed more at maintaining the status quo. Relocating the Bronco's intercooler meant we had to make cuts in the original supporting cast, specifically the grille shutters. The engineers at Ford incorporated additional air ducting in these shutters that keep air flowing through the engine bay and to the intake that we didn't want to compromise. So, we duplicated these ducts to keep things flowing in the right direction.

Airflow is one of the best supporting components to any intercooling system, and we wanted to ensure that our kit keeps the air flowing. So, make sure you stay tuned to see how well the air flows through our kit coming soon!

Keep an eye out towards the end of the month for our dyno results for the 2.7L!

-Nick

So basically, what this guy said:

 

[Mishimoto]

Hello Bronco6G!

I hope everyone had a WONDERFUL holiday season! We're back from our time off with a little bit of a belated Christmas present for you guys in the form of our final dyno data for our high-mount intercooler. We still have some time to go before we kick off our presale, but in the meantime, here's our latest blog post that goes over the performance:

High Road – 2021+ Ford Bronco Performance Intercooler R&D, Part 7 – 2.7L Dyno Testing

The 2.7L Bronco is a true adventure machine. No matter the trim or configuration, these twinturbo V6-powered Broncos are determined to get you to any destination, no matter what's in their way. Well, for the most part. Unfortunately, the intercooler keeping the charged air from those turbos cool isn't exactly up to the task, and it's in the way of more pertinent off-roading gear. So, to retain the 2.7L's sheer determination, we had some better ideas for the intercooler, and now it's time to see how they perform.

In our last post, our 2.3L powered Base model, aka Pedro, was taking point through the tribulations of dyno testing, with our 2.7L following close behind. While these Broncos are headed to the same destination, their route is slightly different. Specifically, where our manual shifting 2.3L used the path of the DynaPacks, our 10-speed automatic equipped 2.7L found its way to our DynoJet system. So while these dynos operate differently, we still perform the same gambit of testing for both platforms.

To refresh those who just came from Pedro's expedition in our last post, our intercooling testing consists of two parts. The first is individual power pulls that provide us with slices of the intercooler's performance for extrapolation. We then simulate the absolute worst conditions possible to put our design through its most grueling test. For both stages, we're comparing the cooling power of our design against the OEM intercooler and the effect that it has on the vehicle's performance.

We start with our power pulls. Typically, we lock the vehicle in the gear closest to a 1:1 gear ratio for this test, but the combo of the 10-speed transmission and 115MPH limiter made this problematic. With this combination, we would be hitting the speed ceiling before we started to collect any results. So, to ensure an accurate range of data, we used 4th gear and sent the Bronco through the rev range at full throttle. We conduct this test multiple times to ensure that our results are consistent and repeatable for accuracy. Next, with our dyno fan simulating 60MPH road wind speeds, we examine the difference in outlet temperatures between the two designs. With our 2.7L on the dyno, we noted a 15°F reduction in outlet temperatures over the stock system.

Now we turn up the heat. Our heat soak test is specifically designed to fill the intercooler with as much heat as possible by stacking up to 6 back-to-back runs together without a cooldown period. As the inlet temperatures rise, we can gauge the real-world cooling performance from the outlet temperatures. Specifically, our high-mounted intercooler maintained a 20°F lower temperature than the stock unit during this torture test.

Charged air cooling is an intercooler's primary task, providing a solid base to build more power on any forced induction platform. Bolt-on power to a factory-tuned vehicle isn't expected, but it's often the beneficial side effect of improved flow and cooler air. Our design's benefit to the system did just that, and we recorded max power gains of 8HP and 10TQ on our stock-tuned 2.7L Bronco.

Adventure is what the Bronco is designed to deliver. The conglomeration of systems are stoked for those jaunts off the asphalt and into the great unknown. The intercooler, on the other hand, is a bit of a homebody. It's overwhelmed by hard work and open spaces, so we're leaving it where it's comfortable and adding a new member to the team. With our intercooler installed, the 2.7L is filled with determination and is back to its confident self, ready to whisk you away on the next expedition. Make sure that you stay tuned for info on how to get yours, coming soon!


-Nick

 

[BAUS67]

Hey @Mishimoto I just got some good news ...................

I am hoping you will have good news soon about your intercooler kit for me as well. I'm all in for that pre-sale, even if the wife don't like it. I got winch and bumpers ready to go. Just need a Bronc and to be able to move that intercooler out of the way.

 

[Mishimoto]

Hey @Mishimoto I just got some good news ...................

I am hoping you will have good news soon about your intercooler kit for me as well. I'm all in for that pre-sale, even if the wife don't like it. I got winch and bumpers ready to go. Just need a Bronc and to be able to move that intercooler out of the way.

This is great news! Stoked to hear your Bronco is in the works! As of right now, it looks like the timing of your delivery and our presale launch are just about lined up

-Nick

 

[BAUS67]

This is great news! Stoked to hear your Bronco is in the works! As of right now, it looks like the timing of your delivery and our presale launch are just about lined up

-Nick

Sounds Great!!!!

Looking at the latest news I have come across a question I have.

The ducting, how important is it??? My plan has been to mount the winch in between the frame rails. (see my crude pics, but it gives you the idea)

Looks like some of the ducting may be ion the way ......... I could mount the winch a bit lower. Maybe just below the lower bar on the bumper.....


The bumper I plan on using is similar in size to the mod bumper.

..........from the backside.

Kinda hard to visualize without a Bronco in front of me. Just trying to formulate a plan of attack before I get my Bronc. Trying to not destroy my approach angle when mounting a winch to front of one of these things.

Let me know what you think.....

 

[Mishimoto]

Sounds Great!!!!

Looking at the latest news I have come across a question I have.

The ducting, how important is it??? My plan has been to mount the winch in between the frame rails. (see my crude pics, but it gives you the idea)

Looks like some of the ducting may be ion the way ......... I could mount the winch a bit lower. Maybe just below the lower bar on the bumper.....


The bumper I plan on using is similar in size to the mod bumper.

..........from the backside.

Kinda hard to visualize without a Bronco in front of me. Just trying to formulate a plan of attack before I get my Bronc. Trying to not destroy my approach angle when mounting a winch to front of one of these things.

Let me know what you think.....

Great question! So we included the ducting more as a means to help guide the fresh air through the intercooler, but you're not going to have a noticeable loss of cooling power if you remove it. It is also actually two pieces to fit both of the OEM bumpers, so you may still be able to get it to fit by removing the front section. But to summarize, the kit will work just as well if you need to ditch that lower duct to fit your planned build.

-Nick

 

[BAUS67]

Great question! So we included the ducting more as a means to help guide the fresh air through the intercooler, but you're not going to have a noticeable loss of cooling power if you remove it. It is also actually two pieces to fit both of the OEM bumpers, so you may still be able to get it to fit by removing the front section. But to summarize, the kit will work just as well if you need to ditch that lower duct to fit your planned build.

-Nick

Cool, good to hear. Thanks Nick.

 

[brokentwig]

Great question! So we included the ducting more as a means to help guide the fresh air through the intercooler, but you're not going to have a noticeable loss of cooling power if you remove it. It is also actually two pieces to fit both of the OEM bumpers, so you may still be able to get it to fit by removing the front section. But to summarize, the kit will work just as well if you need to ditch that lower duct to fit your planned build.

-Nick

Nick @Mishimoto , any chance you guys could provide us with dimensions of that hole that's left in the stock location? I'm with @BAUS67 in wanting to make some plans for what winch will fit in that location.

 

[Mishimoto]

Nick @Mishimoto , any chance you guys could provide us with dimensions of that hole that's left in the stock location? I'm with @BAUS67 in wanting to make some plans for what winch will fit in that location.

Hey @brokentwig - the 'skinniest' dimension between the two intercooler tanks is 17.42 inches. The distance between the two tabs on the black frame horns is 19.92 inches. The distance between the two black frame horns is 21.63 inches (no tabs included). I hope this info helps and am excited to see what you come up with!

Thanks,
John

 

[Bcol2012]

@Mishimoto Maybe I missed it somewhere but did you guys explain where you relocated the ACC? I'm hoping this solution allows for a hidden winch option for the 2.7 but I would still like to utilize my ACC without it being relocated behind a grill if possible.

 

[Ducati1098]

@Mishimoto Maybe I missed it somewhere but did you guys explain where you relocated the ACC? I'm hoping this solution allows for a hidden winch option for the 2.7 but I would still like to utilize my ACC without it being relocated behind a grill if possible.

Maybe I'm incorrect, but I don't think there is any reason to relocate the ACC with either one of their intercoolers. The performance one goes further up behind the grill basically, and the stock location one doesn't interfere with the ACC at all.

 

[Bcol2012]

Maybe I'm incorrect, but I don't think there is any reason to relocate the ACC with either one of their intercoolers. The performance one goes further up behind the grill basically, and the stock location one doesn't interfere with the ACC at all.

Based on the shared pictures I agree with you (and hope that's true). The only reason I ask is because in their first update back in November of 21' it was mentioned they would be relocating the ACC radar. "So, to clear some space for our new design, we’re opting to delete the active grille shutters and relocate the radar cruise control in the name of increased performance. " So figured I'd ask just to get some clarification. I'm also interested to see how radiator temps are effected with the high mount location.

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