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Old 12-01-2015, 04:56 PM   #1
Mishimoto
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Member#: 207954
Join Date: Apr 2009
Default Dropping Intake Temps. Mishimoto 2015 STI FMIC R&D.

We've started a new project for the 2015+ STi. Check out the details on our blog or posted within this thread. Feel free to chime in with any recommendations or comments as we make our way through the R&D process.

http://engineering.mishimoto.com/cat...ercooler-2015/

Dropping Intake Temps. 2015 STI FMIC R&D, Part 1: Core Fitment and Piping Plans

We’ve given the 2015 WRX quite a bit of love, mostly due to the introduction of the FA20DIT within the new chassis. Our team developed a ton of awesome components: a downpipe, an intake system, a couple different intercooler options, and various other neat parts. With our WRX projects mostly wrapped up, it’s time to turn our attention towards the STi. It still has an EJ engine under the hood, but it is mated to a new chassis that many are taking advantage of in various forms of competitive racing.

So far we have developed an intake and a cat-back exhaust for the STI. Our next target is a bolt-on front-mount intercooler (FMIC) kit for the 2015 STI. The EJ25 is a well-respected engine that can make great power from basic bolt-ons and tuning. In addition, the sky is the limit in terms of power output once engine internals are upgraded and a large snail is bolted up. Greater power means more heat, resulting in the need for a more efficient heat exchanger for the charge-air system. Thus, we started our 2015 STI front-mount intercooler project with the goal of supporting vehicles beyond the capacities of an upgraded top-mount cooler.

Core Fitment

We’ve already developed an FMIC setup for the WRX, and since the body of the STI is so similar to the WRX, we were confident we could use our crash beam and intercooler core from the WRX kit. Before progressing with pipe fabrication, however, we needed to check fitment of these WRX parts.
We received a vehicle by way of personal contact among our team members here at Mishimoto. Many thanks to the owner of this STI for lending us his car for development!

Once in the shop, we threw the car on the lift and started with the bumper removal.


Test vehicle on lift for 2015 STI parts development

With the bumper removed, we installed our tube crash beam and front-mount intercooler core from our 2015 WRX direct-fit kit.


Mishimoto’s WRX intercooler installed on the 2015 STI

As expected, both the beam and the heat exchanger bolted up in similar fashion to the WRX. Next up, reinstall the bumper to ensure no clearance issues exist with this large core.


Mishimoto’s 2015 WRX front-mount intercooler installed on the 2015 STI

Check out a closer look!


Mishimoto’s 2015 WRX front-mount intercooler installed on the 2015 STI

All clearances were identical to the WRX, meaning the fitment gets a thumbs up from our engineering department. This core is rated to support vehicles up to around 600 whp. During on-road testing with our shop WRX (300 whp/300 wtq), we saw temperature drops to within a couple degrees of ambient. Pretty impressive, and a very efficient core, making it suitable for use in the STI.

Piping Fabrication

Pipe routing is the unique portion of this project, and it is what will set this kit apart from the WRX components. In an ideal world, we could use the piping setup from our 2008–2014 STI intercooler kit, because it shares the EJ turbocharger layout.


Mishimoto’s 2015 STI parts mock-up

Unfortunately, this is not an ideal world. It looks like only one of the four pipes from the WRX kit will be useable with the STI intercooler kit. We have a lot of fabrication work ahead to snake our piping from the front bumper area to the rear of the engine compartment, but this is a good start to development of our new 2015 STI parts.

Next Update: STI Intercooler Pipe Fabrication

Next time, we will be highlighting the design and fabrication process for our cold-side intercooler pipe assembly. Be sure to check out our blog for other development projects for new 2015 STI parts.

Thanks for reading!
-John
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Old 01-19-2016, 02:05 PM   #2
Mishimoto
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Member#: 207954
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Quick project update!

A Front-Mount for the 2015 STI, Part 2: Cold-Side Intercooler Pipe Fabrication

Our first segment of this STI intercooler project involved the test fitting of our WRX crash beam and intercooler core. We were able to verify fitment of both pieces, which allowed our team to move on to piping fabrication. We are starting this kit with the cold-side pipe, which we’ve decided to place this on the passenger side of the engine bay to reduce the piping length as much as possible. Following this strategy should help reduce lag seen by the driver.

Pipe Fabrication

The cold-side pipe is a great place to start because we are able to use a portion of one of our existing kits. Because the 2015 model shares the EJ from the 2008+, we will be reusing the pipe that attaches to the throttle body and incorporates the BPV (bypass valve).


2015 STI front-mount intercooler development

This pipe provides optimal clearance through its path within the engine bay. It routes from the throttle body into the portion of the engine bay that previously contained the intake airbox.


2015 STI front-mount intercooler development

Our team would be working from the end of this pipe to complete the airflow route to the intercooler.


Throttle body pipe route for STI intercooler development

We then started piecing together our pipe route. This involves careful measurement followed by cutting, fitting, and grinding until the route and fitment are perfect.


2015 STI parts fabrication

After some trial and error, along with test fitting with the bumper in place, we had a completed mock-up pipe.


2015 STI parts fabrication

We then tack-welded each joint on our prototype for additional rigidity.


2015 STI parts fabrication

One final test fit was performed to ensure the accuracy of this prototype.


2015 STI front mount intercooler piping fabrication

At this point we can remove the prototype and collect all the needed dimensional data needed to create a 3D model of our pipe. This will help ensure that our final product corresponds exactly to the design, making for perfect fitment of our STI intercooler kit.

Intake Pipe

You probably noticed in a few of the posted images that an intake pipe and filter are installed. Because of the pipe routing from the engine bay to the front bumper, the stock airbox cannot be reinstalled with this kit.


Intake pipe for STI intercooler kit

As with the pipe attached to the throttle body, we will be stealing this intake setup from our existing 2008–2014 kit. This setup has proven effective and will work well for our 2015 STI front-mount intercooler kit. We will need to modify only the mounting bracket to function with the different engine bay layout on the 2015. Easy!

Coming Up: Hot-Side Pipe Fabrication

Check back soon for a look at the fabrication process for our hot-side pipe!

Keep an eye on our blog for additional development of 2015 STI parts.

Thanks for reading!
-John
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Old 01-23-2016, 07:10 PM   #3
Boxer112
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Location: Yokosuka, Japan (from NY)
Vehicle:
2015 Sti (SOLD)
Crystal White Pearl

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Thank you for contributions to the market and I look forward to further developments.
My question is, why has Mishimoto, and other companies decided to keep the cold side pipe placed over the turbo? Wouldn't it make more sense to keep the cold side cold and not suffer from heat soak during normal city driving?
Will the bend coming off the turbo to the hot pipe cause too much back pressure in the turbo?
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Old 01-23-2016, 08:05 PM   #4
bluemax189
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Quote:
Originally Posted by Boxer112 View Post
Thank you for contributions to the market and I look forward to further developments.
My question is, why has Mishimoto, and other companies decided to keep the cold side pipe placed over the turbo? Wouldn't it make more sense to keep the cold side cold and not suffer from heat soak during normal city driving?
Will the bend coming off the turbo to the hot pipe cause too much back pressure in the turbo?
agreed, a simple elbow off the turbo instead of the 30ft long coupler and a elbow to intake or bend the metal on drivers side to intake manifold.
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Old 02-01-2016, 11:10 AM   #5
Mishimoto
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Member#: 207954
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Quote:
Originally Posted by Boxer112 View Post
Thank you for contributions to the market and I look forward to further developments.
My question is, why has Mishimoto, and other companies decided to keep the cold side pipe placed over the turbo? Wouldn't it make more sense to keep the cold side cold and not suffer from heat soak during normal city driving?
Will the bend coming off the turbo to the hot pipe cause too much back pressure in the turbo?
Quote:
Originally Posted by bluemax189 View Post
agreed, a simple elbow off the turbo instead of the 30ft long coupler and a elbow to intake or bend the metal on drivers side to intake manifold.
Thanks for the comments guys! Ambient temperatures within the engine bay will always be warm, some of this will certainly be attributed to the turbocharger location. Our pipe location was mostly determined based on the bends needed. We wanted to eliminate the need for a 180 degree right off of the turbocharger to route the hot-side towards the passenger side of the vehicle. The decision was made to favor flow/clean aesthetics over the slight impact of heat on intake temperatures. Although some heat will be transferred from the pipe to the air passing through, we do not anticipate this making a significant impact on our actual intake temperatures. This intercooler is capable of dropping temperatures significantly, so only a slight rise should occur as air routes back into the engine bay.

If you still remain concerned about the impact, a heat shield or turbo blanket can be used to provide further protection against turbocharger heat.

Thanks
-John
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Old 02-01-2016, 11:49 AM   #6
Mishimoto
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Project update!

A Front-Mount for the 2015 STI, Part 3: Hot-Side Intercooler Pipe Fabrication


With our cold-side piping complete, it was time to focus on the hot side. This portion of the piping system would require a bit more attention, mainly because we were unable to scavenge any existing pipes from our WRX/STI front-mount intercooler kits (as we did with the cold side). Let’s get to it!

Piping Fabrication

The hot-side piping will route from the turbocharger compressor outlet, around the driver side of the engine bay, and into the front bumper area to attach to the intercooler.

Here is a look at the turbocharger connection point.


2015 STi front-mount intercooler hot-side pipe turbo connection

A coupler attaches the pipe to the turbocharger.

The end of this pipe must attach to our intercooler, which is mounted within the front bumper area. This requires snaking the piping through the engine bay and locating an ideal spot for the piping to travel outside of the engine compartment.


2015 STi Intercooler pipe connection

We should have no issues routing our pipe between the washer reservoir and the body.

Our team started fabrication at this location, which would likely be the most challenging portion of this pipe design process. We started making cuts on our piping and then mocking pieces into place.


2015 STI parts fabrication

The process that followed included making multiple cuts, some trial-and-error for fitment, and soon enough, our work behind the bumper was complete.


2015 STI parts fabrication

With the bumper fitting perfectly, we turned our attention to the piping within the engine bay.


2015 STI parts fabrication

Mating these two pipes became a bit tricky. The battery occupies a large portion of this side of the engine bay and occupies some of the space where we intended to locate our pipe. We could neck the pipe down slightly, but that could result in vibrational noise because clearance would be extremely tight between the pipe and battery.

We found an alternative solution!


2015 STi front-mount intercooler hose fabrication

We will be joining these two portions of the hot-side with a large silicone coupler. This will provide for an easy installation process and will eliminate the chance of noise from vibrations.

This mock-up unit is constructed from three different sections of existing couplers we have in our arsenal. The end product will be a one-piece component designed specifically for this kit.


2015 STi front-mount intercooler hose fabrication

This completed the fabrication phase of our hot-side pipe and coupler assemblies. As with the cold-side pipe, we needed to collect the dimensions from our fabricated prototypes to create 3D models of the features. All piping was tack-welded, and we used our CMM (coordinate measuring machine) to collect all dimensional data.


STI intercooler pipe data collection


STI intercooler pipe data collection

STI intercooler pipe data collection

Coming Up – Final Test Fit and Discounted Pre-Sale

This project is moving along quickly! Within the next few weeks we will be completed with our set of functional prototypes for final product test fitting. Once we are sure everything fits perfectly, we will launch a discounted pre-sale for those interested in picking up a kit.

Keep an eye on our blog for additional 2015 STI parts development.

Thanks for reading!
-John
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Old 02-17-2016, 04:09 PM   #7
Mishimoto
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Project update!

A Front-Mount for the 2015 STi, Part 4: Final Prototype Fitting

Putting together our final prototype was a bit easier for this project compared to other front-mount intercooler (FMIC) kits our team has developed. As mentioned in previous segments, we used the crash beam and intercooler from our 2015 WRX kit. Now we’ve worked up some functional prototype piping for a final test fit.

First, let’s take a quick look at each portion of the kit.

Intercooler and Crash Beam

The intercooler core is the key component in any intercooler kit. This core has provided significant air temperature drops during our testing on the WRX, and we expect the same results with the STi.


Mishimoto STi intercooler and crash beam


Mishimoto STi intercooler and crash beam

This core was engineered to provide an ideal balance between heat transfer and airflow.

Silicone Components


Mishimoto 2015 STi front-mount intercooler silicone hoses

Kit Accessories

A few brackets and some hardware help piece this kit together for a solid, durable installation. We are also including a BPV (bypass valve) adapter flange so we can utilize the stock valve.


Mishimoto 2015 STi front-mount intercooler hardware and accessories

The small, round, CNC-machined component is the sound symposer delete plug. A simple plastic plug would work here, but we decided to flex our CNC muscles to create a more unique plug.


Mishimoto 2015 STi parts

Intake Pipe and Filter

Since our intercooler pipe route passes through the stock airbox, an aftermarket intake must be used. For those of you who don’t already have an aftermarket intake for your STI, we developed an intake pipe and filter setup that are compatible with this FMIC application.


Mishimoto 2015 STi parts


Mishimoto 2015 STi parts

Intercooler Piping

The intercooler piping was the developmental highlight for this project. Let’s take a look at our finished product.


Mishimoto 2015 STi front-mount intercooler piping

From an aesthetic standpoint, the piping looks fantastic. The true test will be when we install these pipes and verify fitment.

Full Kit


Mishimoto STi intercooler kit

Kit Installation

Time to bolt our kit onto the STi and verify fitment.


Mishimoto 2015 STi front-mount intercooler kit installed
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Old 02-17-2016, 04:09 PM   #8
Mishimoto
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Mishimoto STi intercooler kit installed

All components within the engine bay fit perfectly. Our sound symposer delete piece fits nicely and looks fantastic.


Mishimoto 2015 STi parts

One of the challenges encountered with our pipe fabrication centered around the entry into the bumper area due to tight fitment. Thanks to diligence on the part of our engineering team, everything bolted into place perfectly.


Mishimoto 2015 STi parts


Mishimoto STi intercooler kit installed

We’ve built some slight adjustment allowance into this kit to provide for easy installation. Both the intercooler core and piping have flexibility, allowing the user to adjust for great fitment.

Testing Data

Cold weather conditions are not optimal for testing the efficiency of a heat exchanger. Unfortunately, the timing of this project places completion right in the middle of winter.

For now, we will be using our positive results from WRX testing to support this intercooler core. Testing data may vary slightly, however we do expect this kit to drop temperatures in a similar manner.

Below is a temperature plot from our 2015 WRX FMIC testing which compares stock top-mount intercooler (TMIC) outlet temperatures to that of our FMIC.


Outlet temperatures per RPM comparison

Temperatures in the test above rise around 15°F above ambient in our shop, and this is with a low-powered blower fan producing around 30-40 mph wind speeds. This equates to a drop of nearly 40°F compared to the stock intercooler.

Later in the summer we took our testing on the road and we were able to achieve intake temperatures within 3°F of ambient temperatures during the entirety of back-to-back third gear pulls.

We have 100% confidence we will see extremely similar results with the FA20 swapped for the EJ engine in the STi. Once temperatures start rising this year we can begin making plans for some road testing with this kit.

Coming Up – Discounted Pre-Sale

With a successful test fit, we are now ready to move on with producing our first batch of FMIC kits.

A discounted pre-sale will be launching soon for this awesome kit. Keep an eye on our thread for details.

Thanks for reading
-John
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Old 02-25-2016, 08:44 AM   #9
Mishimoto
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Our discounted pre-sale is now live! Check out the details below and let me know if you have any questions.

Pre-Sale Link



Estimated Ship Date: 3/11/2016

Expiration Date: 3/11/2016



Includes:
(1) Bar-And-Plate Intercooler
(1) Steel Crash Bar W/ Mounting Hardware
(2) Hot Side Intercooler Pipes
(2) Cold Side Intercooler Pipes
(1) BPV Flange Adapter
(1) Turbo To Hot Pipe Coupler (for stock turbo)
(1) Turbo To Hot Pipe Coupler (for aftermarket turbo)
(1) 2.25" – 2.5" Silicone Transition Hose
(1) 2.5" – 2.75" Transition Coupler
(1) 2.75" Straight Coupler
(2) 2.5" – 2.75" Intercooler To Pipe Hoses
(1) BPV Recirculation Hose
(2) 1.5" T-Bolt Clamps
(1) 2.00" T-Bolt Clamp
(2) 2.5" T-Bolt Clamps
(4) 2.75" T-Bolt Clamps
(5) 3" T-Bolt Clamps
(1) Bypass Valve Gasket
(2) 6" Of Thermal Wrap
(1) Sound Symposer Plug

Optional Air Intake Kit
(1) Oiled Filter
(1) Aluminum Intake Pipe
(1) 3.00" – 2.75" Transition Coupler
(2) 3" Worm Gear Clamps
(1) Application – Specific Pipe Mounting Bracket













Pre-Sale Link

Let me know if I can answer any questions about our FMIC kit or pre-sale!

Thanks
-John
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Old 03-15-2016, 09:58 AM   #10
Mishimoto
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Thanks for all of the orders guys. Our pre-sale units shipped out last week. Looking forward to the feedback from folks who ordered.

Thanks
-John
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