F-150 intercooler ducting fabrication

Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 4: Intercooler Ducting

In our last entry, we finished the 3D-printing process for our first prototype intercooler. Our team then started the tedious work of modeling all the features we plan to implement and finalizing the details of our intercooler design. During this process, a new idea emerged that would both improve the performance of our cooler and set our kit apart from others.

Let’s dive right in!

F-150 Intercooler Shrouding Fabrication

The footprint of our intercooler core is far larger than that of the stock intercooler. Because of this, it is likely that the airflow supplied by the stock bumper duct is not reaching the entire surface area of our cooler. To combat any issues with loss of airflow, we decided to experiment with some ducting to direct air through the core.

We began the fabrication process with a few old-school techniques; our engineers broke out the template material and a measuring device and started cutting out some ideas.

Ford F-150 EcoBoost intercooler ducting fabrication
Ford F-150 EcoBoost intercooler ducting fabrication

The trial-and-error process began, as we carefully adjusted the templates until they began to take form.

Ford F-150 EcoBoost intercooler ducting fabrication
Ford F-150 EcoBoost intercooler ducting fabrication

Once completed in cardboard, these designs were translated to sheet aluminum for final test fitting. First, check out the horizontally mounted duct that seals the top of the intercooler.

Ford F-150 EcoBoost intercooler ducting fabrication
Ford F-150 EcoBoost intercooler ducting fabrication

The back side of this piece reveals a couple mounting points to attach to the intercooler and other shrouding pieces.

Ford F-150 EcoBoost intercooler ducting fabrication
Ford F-150 EcoBoost intercooler ducting fabrication

We are also lining the edges with weather-stripping to prevent scraping, damage, or vibrational noises. Next, we repeated the same process but for the ducting on the sides of the intercooler, which also had potential airflow issues. Check out our first prototype iteration:

F-150 intercooler ducting fabrication
F-150 intercooler ducting fabrication

Two mounting points on each shroud will attach directly to the intercooler end tank. The single hole towards the point will attach to the horizontal shroud on the top of the cooler.

Here is our finished prototype kit:

F-150 intercooler ducting fabrication
F-150 intercooler ducting fabrication

It will be interesting to see the impact of our additional ducting on actual heat transfer.

Coming Up – 3D Models

Check back in a few weeks for the presentation of our 3D models showing the final intercooler prototype design.

Thanks for reading!

-John

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