We are excited to announce our final revision to our Focus RS intercooler! We’ve gone through three design revisions and this is the perfect design.
[Mounting & Fitment Improvements]
The first prototype core design showed huge efficiency gains vs the OEM unit; however, we saw room for improvement. In the next two prototypes we iterated and improved the end tanks and mounting tabs to further increase the efficiency of the core and ease of install.
After the intercooler had been mounted and driven nearly 1000 miles of road conditions including freeway cruising, data log pulls, dyno time, and spirited drives, we found ways to improve its mounting to the chassis vs the OE. In our final version, we increased the thickness of the mounting tab material from 3mm to 5mm and adding a perpendicular support to the lower tabs for greater strength and durability. This insures a rigid mount to radiator chassis. We also found that utilizing openings in the bumper frame to support the intercooler from the top was much more effective then the OE mounting points; the factory cooler is only suspended from the lower tabs and held vertical by the upper tabs that engage hooks into the casting of the cooler tanks. Due to the increase in weight of our cooler we knew the lower supports would never be sufficient without the extra bracing. To utilize the bumper frame, we installed a bolt and nut through the opening. This was fine for our final prototype but we look forward to using a plastic insert and screw to secure the upper mounts. This will ensure ease of installation with minimal effort.
[Intercooler Performance Testing]
Our upgraded Focus RS intercooler, uses quite a bit more heat removing aluminum vs the OE unit. It is about 30-40% larger by volume and more than 50% larger by mass and surface area vs the OE unit. The performance of the intercooler core of our first prototype was stellar, so final prototype’s core remains the same.
Our Focus RS intercooler upgrade brings intake temps well below 100 degrees F. It doesn’t get terribly hot here in Washington State but we did manage to have a day with an ambient temp of 80 degrees F and a resting 101.9 degrees F. You can see in the graph how the Charge Air Temp (white line) drops rapidly when the throttle body opens. And makes its way back down to 86.7 degrees F when grabbing 3rd gear. That’s great! Many tuners are happy with and consider an intercooler “good” if it can manage to get below 100. The temp does start to climb as expected in the longer gears but as shown in the second graph the charge air temp only climbs 5 degrees to 92 degrees before lifting off the throttle. In comparison, the OE core is much less efficient. We’ve recorded increased charge temps of around 30 degrees F. That means our upgraded Focus RS intercooler around 25 degrees (6x) cooler than the OE intercooler!
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Above is the data log of a 1st through 3rd and into 4th gear acceleration. The white line shows Charge Air Temp. The Charge Air Temp is around 100 degrees F when the throttle plate is closed. The induction air is moving slowly and heat from the engine heats the air. When the throttle plate opens is when the largest drop in Charge Air Temp occurs. Lots of fresh air is let in and the heated induction air passes through quickly. As the vehicle hits 3rd gear it is apparent the turbocharger is now working very hard. There is a slight increase in Charge Air Temp towards the end of 3rd gear. If this data was done without the cooler we would see.
Data log continued (same log as previous graph)
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