Good news! Our first prototype intercooler pipe kit is complete. We can now evaluate both fitment and functionality on our Fiesta. Let’s take a look at each pipe we created.
First we have the more complex pipe of the pair, the cold-side.
Complexity comes in the way of multiple bends combined with numerous pipe-mounted features. To the right side of the pipe, you can see the flat flange that serves as a mounting point for the factory pressure sensor. This flange is CNC-machined to provide a proper seal.
Just down the pipe from this flange you can see a mounting bracket and a nipple. The bracket is a component that may be eliminated from our design. We are evaluating the rigidity of the design with and without the additional bracket to determine if it is needed. The nipple attaches to a quick disconnect vacuum line running throughout the engine bay. Here is another look at the pipe.
The last feature is the symposer port. We had a decent amount of discussion through forums and social media regarding our inclusion of this port. Many customers choose to delete the sound symposer while others will retain it. For this first prototype, we’ve opted to keep it and include a coupler and plug for those who have deleted the system.
In a previous segment of this R&D series, we had discussed the intended benefits of this pipe kit that include power output and improved flow. We will be conducting tests to ensure this is the case; however a physical display of the size and smoothness gives an indication of potential benefits. Check out a couple of comparison images of the stock pipe next to our prototype.
Next up, our hot-side prototype pipe.
Slightly less complex, this pipe combines a couple of bends and one mounting bracket to attach the pipe to a stud on the transmission. The factory pipe mounts in the same fashion. One more look at our hot-side prototype.
The stock hot-side is much smaller than this prototype. Check out a couple of comparison shots showing this!
Not only is the stock pipe multiple pieces, which means the potential for more failure points, but it also necks down to 1.5” piping between the resonator and turbo connection point. Our piping is 2.5” in diameter from the turbo to the intercooler.
Along with the piping kit, we also designed a few FIST-specific boots to create robust connection points between the piping, intercooler, and turbocharger.
The boots we designed are constructed from 5-ply silicone, capable of any boost pressure you intend to run through the 1.6L. The two outer boots shown are the connection points between the intercooler and pipes. The boot second from the left is the turbo connection point. One boot is missing from this image, our throttle-body boot. This will be included in the final kit as well.
The smallest coupler in this image is our symposer delete inclusion. When installed along with the CNC-machined plug, these pieces eliminate the functionality of the stock symposer system.
One more look at the components created during our first stage of prototyping.
Coming Up – Prototype Test Fitting
Next time we will be bolting these pipes into place on our FIST to check fitment and make any necessary design adjustments.
Keep an eye on our blog for more awesome updates on Mishimoto Fiesta ST performance parts.
Thanks for reading!