Mustang EcoBoost Intercooler Pipe R&D, Part 2: 3D Models and BPV Port Prototyping
Interested in picking up our Mustang EcoBoost Intercooler Pipe Kit? Check out more details on our product page linked below!
3D Pipe Models
As with all our projects, we would be using 3D modeling software (Solidworks) to put our final design into both 3D and drawing forms. Not only does this put our design into a viewable format, but it also allows for digital tweaks as well as confirmation of fitment and precision with the overall product design.
Check out the rendering below showing our projected cold-side pipe design.
Ford made this one fairly easy for us. This pipe features a pretty smooth shape and routes from the intercooler to the throttle body. An aluminum counterpart is going to be a huge improvement over the stock rubber hose referenced in the last post. Each connection point will be secured with a Mishimoto silicone coupler and our T-bolt clamps for a solid connection. Note the bead roll on the end of our pipe for added holding strength for the coupler.
One additional feature you may notice is the bung on the top of the pipe. We are including this bung on the pipe for use with meth injection or as an additional pressure/temperature sensor. This bung is not predrilled, but it does provide the option for users who require it. Pretty slick!
On to our hot-side pipe model.
The hot-side pipe presented a bit more of a challenge in terms of emulating the stock pipe. The shape was rather simple to replicate, but that pesky BPV flange was quite a challenge. We wanted our pipe to be completely compatible with the stock BPV unit so we would have a bolt-on upgrade. To do this we collected dimensional information on the stock piece so we could design this component in 3D.
We then utilized our 3D printer to print the flange we designed so we could confirm fitment with the stock BPV unit. Check out the prototype!
Once printed, we fit this unit to the stock BPV to ensure proper fitment. With all dimensions confirmed, we were ready to construct a set of final prototype pipes to give this kit the thumbs up for mass production.
Check back next week for a look at our final pipes and information regarding our discounted presale for this awesome kit!