Ecoboost Performance Forum

Vehicle Specific Boards => Explorer Sport => Performance Upgrades => Topic started by: Ls2bait on March 06, 2020, 01:10:46 PM

Title: Any Explorer Sport intercoolers available?
Post by: Ls2bait on March 06, 2020, 01:10:46 PM
Iím seeing aftermarket intercoolers for every ecoboost platform except the explorer. Does anyone know if they make better ones for these? Iíd like to get a little more power out of this puppy.
Title: Re: Any Explorer Sport intercoolers available?
Post by: SM105K on March 06, 2020, 01:12:30 PM
I would ask Matt at Gearhead if the SHO intercooler would work.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Jordan on March 06, 2020, 02:56:58 PM
I would ask Matt at Gearhead if the SHO intercooler would work.

It does not. No current aftermarket intercoolers that bolt in for the explorer
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ls2bait on March 06, 2020, 04:21:45 PM
Well thatís a bummer. Iím getting about 14.5 psi now with the tune but the IATís are definitely climbing.
Title: Re: Any Explorer Sport intercoolers available?
Post by: SuperPete on March 07, 2020, 11:27:22 AM
My buddy sho has 2014 explorer sport actually looking for one, found this guy,  http://csfimports.com/tag/intercoolers/ (http://csfimports.com/tag/intercoolers/)
On eBay they go for $175 shipped

This is same company that makes intercoolers for Gearhead as well,
I just don't know if GearHead tune will benefit out of this IC

Title: Re: Any Explorer Sport intercoolers available?
Post by: 97novi2k on April 04, 2020, 11:22:35 AM
Really wish the Gearhead intercooler would work as I want one for my sport as well. What is the big difference as to why it wonít work?
Title: Re: Any Explorer Sport intercoolers available?
Post by: plattcr1 on May 27, 2020, 07:21:18 PM
I'm wanting the same!! Spoke with Gearhead the other day and they are apparently in the R&D stages of making a custom fit IC for the Explorer Sport (16-18). Unfortunately, they couldn't give me any time frame, which is disappointing. However, I have had a few good conversations with a very serious Exp mod guy who has installed the Mishi J universal intercooler with minimal bracket mods. Waiting to hear about the performance results to see if I wan t to try this.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 12, 2020, 09:03:56 PM
I'm wanting the same!! Spoke with Gearhead the other day and they are apparently in the R&D stages of making a custom fit IC for the Explorer Sport (16-18). Unfortunately, they couldn't give me any time frame, which is disappointing. However, I have had a few good conversations with a very serious Exp mod guy who has installed the Mishi J universal intercooler with minimal bracket mods. Waiting to hear about the performance results to see if I wan t to try this.
Matt has been talking about this intercooler for a very long time, lol. I'm not holding my breath....there are a few folks doing some Frankenstein/DIY ones but haven't heard how they are working out just yet.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 12, 2020, 09:06:44 PM
Really wish the Gearhead intercooler would work as I want one for my sport as well. What is the big difference as to why it wonít work?
They are completely different in size, shape, hose routing, bolt up locations. Believe it or not, real estate is at a premium in the XSport...its pretty tight behind that bumper...

Yes, the smaller one is actually the XSport. One of the reasons our IATs are more difficult manage than in the SHO.

OEM intercoolers:
(https://uploads.tapatalk-cdn.com/20200713/dbc2c4b2b5224e487cd2a4e9c7283947.jpg)(https://uploads.tapatalk-cdn.com/20200713/1b7fbad7b59898cec98baf383376bae0.jpg)

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 24, 2020, 11:59:34 AM
So I did discover the 2019 2.3L Ranger has the stock intercooler as the Explorer Sports. Levels (https://levelsperformance.com/products/2019-ford-ranger-ecoboost-intercooler-upgrade) makes an upgraded intercooler for the Ranger. I'm awaiting a reply to see the dimensions to see if we have a possible fitment.

I also have my 2.0L EB Fusion Steeda intercooler that I will see how much of a difference it is compared to the stock Sports.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 24, 2020, 12:08:00 PM
So I did discover the 2019 2.3L Ranger has the stock intercooler as the Explorer Sports. Levels (https://levelsperformance.com/products/2019-ford-ranger-ecoboost-intercooler-upgrade) makes an upgraded intercooler for the Ranger. I'm awaiting a reply to see the dimensions to see if we have a possible fitment.

I also have my 2.0L EB Fusion Steeda intercooler that I will see how much of a difference it is compared to the stock Sports.
Hmmm very nice find...let me know what you find out.

EDIT: I just checked out their IC for the Ranger..I'm trying to think how it would work without some included plumbing as the in/out isn't at the same angles to accept OEM couplers.  But went to Tasca to cross-refernce part numbers and you're right, they both have the same number and will fit on each others platform...

The radiator core support looks very different than the XSport one so maybe it won't fit simply because of everything in the way...hmm...really interesting though...

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Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 24, 2020, 12:26:44 PM
Doing more research and starting to wonder if this won't actually work.  Although Tasca lists the parts number are interchangeable..here is a pic of the stock Ranger IC (on the right):

(https://www.garrettmotion.com/wp-content/uploads/2019/07/Garrett_Performance_Ranger_Intercooler_Comparison.jpg)

This isn't what the inlet tube of the stock XSport looks like at all, not at all.  Different angles. So I wonder what is going on here...hmmm...

BTW, turns out there a few options out there for upgrade Ranger ICs. Just a few:

https://www.mountuneusa.com/1400-IC-AA-p/1400-ic-aa.htm

https://www.garrettmotion.com/racing-and-performance/performance-catalog/intercoolers/3-2l-ford-raptor-ranger-everest-mazda-bt50-performance-intercooler/

Title: Re: Any Explorer Sport intercoolers available?
Post by: Macgyver on July 24, 2020, 01:26:17 PM
Getting it coupled up would seem to be the easy part. If that IC could be mounted in the factory spot. You can cut weld buy etc.

http://www.siliconeintakes.com
Title: Re: Any Explorer Sport intercoolers available?
Post by: GotGrip? on July 24, 2020, 04:55:14 PM
Well thatís a bummer. Iím getting about 14.5 psi now with the tune but the IATís are definitely climbing.

The explorer platform from what I've seen with them apart would be incredibly easy to DIY. It would be almost similar to the set up I have a few others like 802 and Aaron, and It didn't look like it would require cutting but I could be wrong. We might end up with one next year and if that's the case, it will go on at the same time as the tune.
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 05:36:16 AM
Doing more research and starting to wonder if this won't actually work.  Although Tasca lists the parts number are interchangeable..here is a pic of the stock Ranger IC (on the right):

This isn't what the inlet tube of the stock XSport looks like at all, not at all.  Different angles. So I wonder what is going on here...hmmm...

BTW, turns out there a few options out there for upgrade Ranger ICs. Just a few:

https://www.mountuneusa.com/1400-IC-AA-p/1400-ic-aa.htm

https://www.garrettmotion.com/racing-and-performance/performance-catalog/intercoolers/3-2l-ford-raptor-ranger-everest-mazda-bt50-performance-intercooler/

Raptor Ranger intercooler? That one looks a bit better than stock and looks like it would fit. The Garrett looks like it would be a bit thick.

The Mountune dimensions look like it's only an inch thicker. Gearhead is designing one currently and will release it in late summer if it makes it to the market. Either way it looks like we may have sort of an upgrade.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 07:39:53 AM
Doing more research and starting to wonder if this won't actually work.  Although Tasca lists the parts number are interchangeable..here is a pic of the stock Ranger IC (on the right):

This isn't what the inlet tube of the stock XSport looks like at all, not at all.  Different angles. So I wonder what is going on here...hmmm...

BTW, turns out there a few options out there for upgrade Ranger ICs. Just a few:

https://www.mountuneusa.com/1400-IC-AA-p/1400-ic-aa.htm

https://www.garrettmotion.com/racing-and-performance/performance-catalog/intercoolers/3-2l-ford-raptor-ranger-everest-mazda-bt50-performance-intercooler/

Raptor Ranger intercooler? That one looks a bit better than stock and looks like it would fit. The Garrett looks like it would be a bit thick.

The Mountune dimensions look like it's only an inch thicker. Gearhead is designing one currently and will release it in late summer if it makes it to the market. Either way it looks like we may have sort of an upgrade.

Yeah I wouldn't hold my breath on the GH one. I've been asking about that one for about a year and a half or so and it's always "still in development". Hell, I just asked last week for an update and asked to be a beta tester if they need one. Anyway, hope it's true, but I'm not putting money on it.

As for thickness we can only go to 3.5 roughly, there isn't much more room than that.

And I only showed that pic to illustrate that, short of figuring out some crazy coupling adjustment with silicone hose, the angles of the inlet and outlet do not match the Explorers. I dont really think the Ford Ranger option will be viable tbh.

But hey, I could be wrong...I guess I'm being pessimistic about it.

I'm going a whole different direction myself. I'm just going one-off and going to have the guy who did my exhaust just do my entire intake system. Minimal silicone connectors but using Wiggins clamp connection points instead. Already in the planning stages but still a ways out for me.

Anyway keep me updated on what you find out.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: 802SHO on July 25, 2020, 08:34:11 AM
Doing more research and starting to wonder if this won't actually work.  Although Tasca lists the parts number are interchangeable..here is a pic of the stock Ranger IC (on the right):

This isn't what the inlet tube of the stock XSport looks like at all, not at all.  Different angles. So I wonder what is going on here...hmmm...

BTW, turns out there a few options out there for upgrade Ranger ICs. Just a few:

https://www.mountuneusa.com/1400-IC-AA-p/1400-ic-aa.htm

https://www.garrettmotion.com/racing-and-performance/performance-catalog/intercoolers/3-2l-ford-raptor-ranger-everest-mazda-bt50-performance-intercooler/

Raptor Ranger intercooler? That one looks a bit better than stock and looks like it would fit. The Garrett looks like it would be a bit thick.

The Mountune dimensions look like it's only an inch thicker. Gearhead is designing one currently and will release it in late summer if it makes it to the market. Either way it looks like we may have sort of an upgrade.

Yeah I wouldn't hold my breath on the GH one. I've been asking about that one for about a year and a half or so and it's always "still in development". Hell, I just asked last week for an update and asked to be a beta tester if they need one. Anyway, hope it's true, but I'm not putting money on it.

As for thickness we can only go to 3.5 roughly, there isn't much more room than that.

And I only showed that pic to illustrate that, short of figuring out some crazy coupling adjustment with silicone hose, the angles of the inlet and outlet do not match the Explorers. I dont really think the Ford Ranger option will be viable tbh.

But hey, I could be wrong...I guess I'm being pessimistic about it.

I'm going a whole different direction myself. I'm just going one-off and going to have the guy who did my exhaust just do my entire intake system. Minimal silicone connectors but using Wiggins clamp connection points instead. Already in the planning stages but still a ways out for me.

Anyway keep me updated on what you find out.

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Yes, have that guy run everything and make it....from looking at his work it wouldn't be a problem at all for the guy.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 08:29:37 PM
If the 2.3L Ranger is the same as the Explorer's and the Raptors just looks a bit thicker, what reason are you thinking that it wouldn't work? The Mountune dimensions also are within the 3.5" you stated we approximately have behind the grille.

I think we would see much more power like the SHO's if we had a better intercooler.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 09:47:36 PM
If the 2.3L Ranger is the same as the Explorer's and the Raptors just looks a bit thicker, what reason are you thinking that it wouldn't work? The Mountune dimensions also are within the 3.5" you stated we approximately have behind the grille.

I think we would see much more power like the SHO's if we had a better intercooler.
Ok, just look at photos of both of them and you will understand what I'm trying to tell you.  Granted, I don't know for sure that it won't fit. All I'm saying is, if you look at both intercoolers (even though they show the same part number), their inlet and outlet tubes are not in the same orientation and their mounting locations look very different. That's not to say there isn't some way to make it work, but it doesn't look plug and play to me.

And yes, I completely agree that a better IC would benefit our platform. My IATs are pretty high right now. Methanol will facilitate that but it would be nice to have a more efficient IC.

I am going the custom one-off route at this point, but it would be intriguing if the Ranger one could fit. I won't be trying it, but if you do, let me know your results. Would be great info to know.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 10:29:44 PM
I'm starting to think that the Ranger has a different intercooler entirely.

Mountune has the Ranger factor IC listed as 25"L x 9.88H" x 2.48"D.

Partsgeek has the TYC IC listed as 25.91"L x 6.21" H x 2.52"D. Both inlet/outlet tubes are 2.52".

Seems that we had a website misleading with having the Ranger incorrectly listed.

Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 10:33:48 PM
I'm starting to think that the Ranger has a different intercooler entirely.

Mountune has the Ranger factor IC listed as 25"L x 9.88H" x 2.48"D.

Partsgeek has the TYC IC listed as 25.91"L x 6.21" H x 2.52"D. Both inlet/outlet tubes are 2.52".

Seems that we had a website misleading with having the Ranger incorrectly listed.
That's what I've been trying to tell you. Although I didn't get the dimensions you listed, I just took one look at both ICs and saw they were different.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 10:36:24 PM
Doing some research, Mishimoto J-Line is listed as 22.0" x 7.2" x 3.5". It's not as long but using a 90 degree elbow would probably allow it to fit pretty well. I wonder if that 1" extra height would interfere with anything.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 10:37:01 PM
Doing some research, Mishimoto J-Line is listed as 22.0" x 7.2" x 3.5". It's not as long but using a 90 degree elbow would probably allow it to fit pretty well. I wonder if that 1" extra height would interfere with anything.
Yes, there are 2 explorers I know of using that IC

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 10:38:53 PM
How are their temps looking? With elbows it wouldn't be hard to get the weird angle we have on our stock IC with a silicone elbow.

I'm going to have to take my bumper off this coming week and see what kind of room there is.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 10:40:56 PM
Yes, there are 2 explorers I know of using that IC

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How are their temps looking? With elbows it wouldn't be hard to get the weird angle we have on our stock IC with a silicone elbow.

I'm going to have to take my bumper off this coming week and see what kind of room there is.
[/quote]That idk, I was in contact with one of the guys, but he has since not been responding. So not sure how it is doing. Here's pix I got sent of their setup. I have no details other than this, so not sure on any more than this.(https://uploads.tapatalk-cdn.com/20200726/3ef337cceccbf83c24ab7752d0c913d0.jpg)(https://uploads.tapatalk-cdn.com/20200726/9aaa11f943c834ba842ba8f70fef61c2.jpg)

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 10:46:53 PM
Yes, there are 2 explorers I know of using that IC

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How are their temps looking? With elbows it wouldn't be hard to get the weird angle we have on our stock IC with a silicone elbow.

I'm going to have to take my bumper off this coming week and see what kind of room there is.
That idk, I was in contact with one of the guys, but he has since not been responding. So not sure how it is doing. Here's pix I got sent of their setup. I have no details other than this, so not sure on any more than this.(https://uploads.tapatalk-cdn.com/20200726/3ef337cceccbf83c24ab7752d0c913d0.jpg)(https://uploads.tapatalk-cdn.com/20200726/9aaa11f943c834ba842ba8f70fef61c2.jpg)

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[/quote]

It would be nice if we could get more information and maybe the links to the pieces he used too. Either way that 1" extra thickness of the core would probably help out quite a bit.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 25, 2020, 10:48:15 PM
Yes, there are 2 explorers I know of using that IC

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How are their temps looking? With elbows it wouldn't be hard to get the weird angle we have on our stock IC with a silicone elbow.

I'm going to have to take my bumper off this coming week and see what kind of room there is.
That idk, I was in contact with one of the guys, but he has since not been responding. So not sure how it is doing. Here's pix I got sent of their setup. I have no details other than this, so not sure on any more than this.(https://uploads.tapatalk-cdn.com/20200726/3ef337cceccbf83c24ab7752d0c913d0.jpg)(https://uploads.tapatalk-cdn.com/20200726/9aaa11f943c834ba842ba8f70fef61c2.jpg)

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It would be nice if we could get more information and maybe the links to the pieces he used too. Either way that 1" extra thickness of the core would probably help out quite a bit.
[/quote]

Yeah, I've been reaching out to him, but he's dropped out of contact, so I have no more info.  If he hits me back, I'll see if he can pass on the info.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 25, 2020, 10:56:03 PM
Well just doing quick math on the core sizes of the two, the stock is 405.471 in^3 and the Mishimoto is 554.4 in^3.
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 26, 2020, 07:56:44 PM
I ordered the Mishimoto J-Line and a handful of couplers and elbows. Should have everything in by Wednesday so I plan on taking my old intercooler out to get everything ready for the install on Tuesday.

Will update on results if the fittings I purchased are the correct ones.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 26, 2020, 08:00:18 PM
I ordered the Mishimoto J-Line and a handful of couplers and elbows. Should have everything in by Wednesday so I plan on taking my old intercooler out to get everything ready for the install on Tuesday.

Will update on results if the fittings I purchased are the correct ones.
Nice!

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 28, 2020, 05:58:09 PM
Well the intercooler arrived today but I doubt itís going to get installed. Bought it from Amazon as new and hereís what Iíve discovered. The box was open, the bolts for the mounting were out of the bag (bag was ziplock and closed), there is damage to the intercooler and the ďMĒ is missing on the front of the intercooler. Itís definitely a Mishimoto but what the hell is going on with this?

Next one is supposed to be delivered by Thursday, along with my aFe intake.

(https://uploads.tapatalk-cdn.com/20200728/25a61f503eb2525c9d486f19795dd6e1.jpg)
(https://uploads.tapatalk-cdn.com/20200728/0c1aa1de7a48bc5447c737a2d3a267ef.jpg)
(https://uploads.tapatalk-cdn.com/20200728/9425539f12771f25f73d89156582d2c5.jpg)
(https://uploads.tapatalk-cdn.com/20200728/211268c1c46f9efdfac1c7784a426c23.jpg)
Title: Re: Any Explorer Sport intercoolers available?
Post by: 802SHO on July 28, 2020, 07:37:12 PM
Well the intercooler arrived today but I doubt itís going to get installed. Bought it from Amazon as new and hereís what Iíve discovered. The box was open, the bolts for the mounting were out of the bag (bag was ziplock and closed), there is damage to the intercooler and the ďMĒ is missing on the front of the intercooler. Itís definitely a Mishimoto but what the hell is going on with this?

Next one is supposed to be delivered by Thursday, along with my aFe intake.

(https://uploads.tapatalk-cdn.com/20200728/25a61f503eb2525c9d486f19795dd6e1.jpg)
(https://uploads.tapatalk-cdn.com/20200728/0c1aa1de7a48bc5447c737a2d3a267ef.jpg)
(https://uploads.tapatalk-cdn.com/20200728/9425539f12771f25f73d89156582d2c5.jpg)
(https://uploads.tapatalk-cdn.com/20200728/211268c1c46f9efdfac1c7784a426c23.jpg)
Huh almost like someone else returned it and they sent it to you.  Definitely ship it back


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Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 28, 2020, 07:57:03 PM
Yeah that's kinda shitty

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 30, 2020, 12:10:27 AM
Well I made some progress today. I took over 50 bolts/screws out to get to the intercooler. Also removed the actual bumper which involves drilling a few holes and 8 bolts.

The issue I see people having not wanting to do this is the shroud for the condenser/ intercooler needing to be removed. Shown below is the part that interferes.

(https://uploads.tapatalk-cdn.com/20200730/a7f0d7497c0522a22f7dfdcdd3de05b3.plist)

My condenser has taken a beating as you can see where the bumper cover does and doesnít cover. So what I did was ďmodifyĒ the shroud .

(https://uploads.tapatalk-cdn.com/20200730/814690915bb81198f6040c61b4c58cbd.jpg)

Iíll be covering those spots back up with some semi-flexible clear acrylic Iíll drill and bolt down to the shroud.

(https://uploads.tapatalk-cdn.com/20200730/b3d8c89a009e51c43592f662896d4812.jpg)

Thereís the difference between the two right now. Iím awaiting the replacement thatís coming in tomorrow and I work the next 4 days so Iíll be doing a little bit installation each night. It does sit right up in place so I donít think Iíll have fitment issues.

Also tearing this down, these charge pipes are a joke. I think Iíll be buying the Eco Power Parts charge pipes down the road see how many bends and how thin the stock ones are.

Also discovered my driver rear wheel bearing needs replaced after doing a 4 corner brake job today. Timken replacement for $114 isnít bad, considering local Auto parts stores want well over that any brand they offer.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 30, 2020, 12:36:35 AM
Well I made some progress today. I took over 50 bolts/screws out to get to the intercooler. Also removed the actual bumper which involves drilling a few holes and 8 bolts.

The issue I see people having not wanting to do this is the shroud for the condenser/ intercooler needing to be removed. Shown below is the part that interferes.

(https://uploads.tapatalk-cdn.com/20200730/a7f0d7497c0522a22f7dfdcdd3de05b3.plist)

My condenser has taken a beating as you can see where the bumper cover does and doesnít cover. So what I did was ďmodifyĒ the shroud .

(https://uploads.tapatalk-cdn.com/20200730/814690915bb81198f6040c61b4c58cbd.jpg)

Iíll be covering those spots back up with some semi-flexible clear acrylic Iíll drill and bolt down to the shroud.

(https://uploads.tapatalk-cdn.com/20200730/b3d8c89a009e51c43592f662896d4812.jpg)

Thereís the difference between the two right now. Iím awaiting the replacement thatís coming in tomorrow and I work the next 4 days so Iíll be doing a little bit installation each night. It does sit right up in place so I donít think Iíll have fitment issues.

Also tearing this down, these charge pipes are a joke. I think Iíll be buying the Eco Power Parts charge pipes down the road see how many bends and how thin the stock ones are.

Also discovered my driver rear wheel bearing needs replaced after doing a 4 corner brake job today. Timken replacement for $114 isnít bad, considering local Auto parts stores want well over that any brand they offer.
Nice. So you had to cut the core support to take out the stock IC or because its the only way to fit the larger aftermarket IC you got?

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 30, 2020, 05:37:58 AM
Well I did it in ordered to not remove the condenser and AC lines. Since my AC works well, I didnít feel like tampering with draining the refrigerant and cleaning up that mess.

Hopefully tonight I can get most of it installed and secured in place.

I just really hope this new intercooler comes with the ďMĒ so there is some indication that itís a modified FMIC, I mean having no damage to it as well is the main part of getting the replacement. Not many people are going to be suspecting this Sport is going to be able to pull on them!

When do you plan on getting you phenolic spacer and manifold setup installed? Iím curious to know if the spacer really does help prevent heat soak better and if there are power gains from the spacer increasing volume too.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 30, 2020, 07:13:16 AM
Well I did it in ordered to not remove the condenser and AC lines. Since my AC works well, I didnít feel like tampering with draining the refrigerant and cleaning up that mess.

Hopefully tonight I can get most of it installed and secured in place.

I just really hope this new intercooler comes with the ďMĒ so there is some indication that itís a modified FMIC, I mean having no damage to it as well is the main part of getting the replacement. Not many people are going to be suspecting this Sport is going to be able to pull on them!

When do you plan on getting you phenolic spacer and manifold setup installed? Iím curious to know if the spacer really does help prevent heat soak better and if there are power gains from the spacer increasing volume too.
Nice! Yeah, just waiting on the spacer to do all that installation. I'm not counting on very big gains tbh. My biggest hope for it is to keep some heat down, and even that, idk how much. It's a bit of am experiment as there isnt much data out there on it. You should see pretty nice gains with that new IC, though. IATs are pretty high. I'm going to be doin the one off install, so I'm still waiting, but I agree, the  charge piping is pretty pathetic. Lol

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Title: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 30, 2020, 09:48:17 PM
Having lower temps will condense the air more efficiently and having a well made FMIC like Mishimoto will provide less pressure drop at higher RPMs also providing more boost.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 30, 2020, 09:49:28 PM
Having lower temps will condense the air more efficiently and having a well made FMIC like Mishimoto will provide less pressure drop at higher RPMs also providing more boost.
Lol, thank you, yes I'm familiar with how an IC works...

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Title: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 31, 2020, 05:30:27 AM
Having lower temps will condense the air more efficiently and having a well made FMIC like Mishimoto will provide less pressure drop at higher RPMs also providing more boost.
Lol, thank you, yes I'm familiar with how an IC works...

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Well then why arenít you expecting much of a gain? Seeing the dyno numbers on a SHO with the same mods, the Sports arenít seeing anywhere close to those  numbers and the main limiting factor is our intercooler.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on July 31, 2020, 07:15:52 AM
Having lower temps will condense the air more efficiently and having a well made FMIC like Mishimoto will provide less pressure drop at higher RPMs also providing more boost.
Lol, thank you, yes I'm familiar with how an IC works...

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Well then why arenít you expecting much of a gain? Seeing the dyno numbers on a SHO with the same mods, the Sports arenít seeing anywhere close to those  numbers and the main limiting factor is our intercooler.

Huh? Not expecting gains? Where did I say that? Not sure what you're talking about. I'm VERY cognizant of how pathetic our IC is and how limiting it is.

I just have WAY bigger plans for my IC setup that I haven't gotten to yet.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on July 31, 2020, 07:21:25 AM
Having lower temps will condense the air more efficiently and having a well made FMIC like Mishimoto will provide less pressure drop at higher RPMs also providing more boost.
Lol, thank you, yes I'm familiar with how an IC works...

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Well then why arenít you expecting much of a gain? Seeing the dyno numbers on a SHO with the same mods, the Sports arenít seeing anywhere close to those  numbers and the main limiting factor is our intercooler.
Huh? Not expecting gains? Where did I say that?

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Yeah about that, we were talking about the manifold spacers and for some reason I read that this morning as if you were speaking of the FMIC, my fault!

I wanted to get more work done last night since the new Mishimoto came in undamaged and packed differently, as if it was actually new this time. It's still missing the "M" logo on the front, which isn't a big deal but still misrepresented in every single picture of it.  I was going to run and grab some new clamps last night, but couldn't make it to the hardware store yet.
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 01, 2020, 07:53:29 AM
Here it is installed.

(https://uploads.tapatalk-cdn.com/20200801/f81e62a4f08d2152530e37c82bba2c57.jpg)

Had to work today so I wasnít able to do any driving to test temps but that will be tonight. Fits like a glove.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 01, 2020, 08:24:26 AM
Here it is installed.

(https://uploads.tapatalk-cdn.com/20200801/f81e62a4f08d2152530e37c82bba2c57.jpg)

Had to work today so I wasnít able to do any driving to test temps but that will be tonight. Fits like a glove.
Looks good. You should make a parts list of what was actually used. Where'd you order everything from and about how much you spent.

Btw, the bumper crash bar is upside down from the looks of it. At least on mine, that tow hook bolt hole goes on the passenger side. There's a hole in the bumper that allows access to it.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 01, 2020, 08:40:17 AM
Yeah I realized that before I bolted it down but I was just doing a test fit to see if I had any clearance issues.

Mishimoto - MMINT-UJB Universal Intercooler J-Line, Black - $257.52

(1) HPS AJ400-225 6061 T6 Aluminum Joiner Tubing with Bead Roll, 16 Gauge, 4" Length, 2.25" OD, 0.065" Wall Thickness - $16.43

(1) HPS AJ300-250 6061 T6 Aluminum Joiner Tubing with Bead Roll, 16 Gauge, 3" Length, 2.5" OD, 0.065" Wall Thickness - $16.50

(2) Ispeedytech 2.5" Performance 90 Degree Tight Radius hose Cast Aluminum Turbo Elbow pipe 63 mm - $16.99/each

(3) 2.5" ID Straight Silicone Hose Coupler, High Temp 4-Ply Reinforced - 131-06303-0401 - Ticon Industries - $7.45/each

(1) Mishimoto 2.25" to 2.5" Silicone Transition Coupler, Black - $11.00

$357.78 total without taxes and shipping was free.

I did quite a bit of cutting of the shroud but I don't see any detrimental effects of doing so. Also I only went with the Mishimoto fitting because the HPS brand wouldn't of gotten here during the time I wanted to install, not like it matters at all.

 
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 01, 2020, 08:57:29 AM
Awesome. That's a damn good price. Interested in seeing your IATs now. Did you happen to take any logs before the change?

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 01, 2020, 10:11:59 AM
I didn't do any logs, but I can say with certainty that my temps were no less than 20f above ambient while cruising on the highway. This was with my Livernois Mycal Touch and using the gauges on that, so I can't verify how accurate that reading is. I always have the gauges on while I drive so I do monitor them constantly.

I'm still contemplating painting something on the front of the FMIC before I put the bumper cover on since the "M" on the pictures were highly misleading (still bitter about it). Maybe do an "EX" or "X" in white to match my paint.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 01, 2020, 10:26:57 AM
I didn't do any logs, but I can say with certainty that my temps were no less than 20f above ambient while cruising on the highway. This was with my Livernois Mycal Touch and using the gauges on that, so I can't verify how accurate that reading is. I always have the gauges on while I drive so I do monitor them constantly.

I'm still contemplating painting something on the front of the FMIC before I put the bumper cover on since the "M" on the pictures were highly misleading (still bitter about it). Maybe do an "EX" or "X" in white to match my paint.
Nice...I've always been into a straight aluminum, non painted, exposed IC. Just looks like it means all business.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 01, 2020, 11:11:14 AM
I was thinking about the unpainted one but having the condenser black and the grille black as well I decided against ordering it. Probably will end up not painting it since my Sport looks completely stock still.
Title: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 02, 2020, 09:37:33 AM
Got the bumper cover installed last night with no issues. Pretty close to the limit on the thickness of the core but no rubbing or fitment issues. Definitely feels like it pulls harder through the gears but I wasnít trying to push my vehicle too hard just yet, that will be done on the way home.

One thing to note, when cursing at 65 and letting off, I noticed the ACT 2 that goes into the manifold increased temps by 6-8 degrees, putting it where stock was just cruising. Only thing I can think of would be the heat from the engine bay is transferring faster to the manifold since ours in aluminum. After letting off and accelerating the ACT 2 temp drops which is indicating the air from the intercooler is cooling off the manifold, unlike I witnessed before.

Either way the temps have dropped and I will be calculating the max boost I have since Livernois shows raw data with in Hg instead of PSI.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 02, 2020, 11:11:28 AM
Got the bumper cover installed last night with no issues. Pretty close to the limit on the thickness of the core but no rubbing or fitment issues. Definitely feels like it pulls harder through the gears but I wasnít trying to push my vehicle too hard just yet, that will be done on the way home.

One thing to note, when cursing at 65 and letting off, I noticed the ACT 2 that goes into the manifold increased temps by 6-8 degrees, putting it where stock was just cruising. Only thing I can think of would be the heat from the engine bay is transferring faster to the manifold since ours in aluminum. After letting off and accelerating the ACT 2 temp drops which is indicating the air from the intercooler is cooling off the manifold, unlike I witnessed before.

Either way the temps have dropped and I will be calculating the max boost I have since Livernois shows raw data with in Hg instead of PSI.
Very cool.

I would lose LMS as fast as you can, btw. Just FYI...switch to AJP or GH...

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Title: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 02, 2020, 10:00:12 PM
Maybe when I start getting into more intensive mods but my issue now is that aFe intake pulling in too much hot air. Switching back to the stock filter with a k&N drop in to see how much cooler it runs. I was seeing higher temps in town on my air intake vs the manifold.

Going up Pikes Peak tomorrow so I should be able to get some good numbers with the stock air box.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 02, 2020, 11:57:46 PM
Hmmm interesting find. Keep us posted. Good work, btw.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 07, 2020, 12:53:30 PM
Drove about 800 miles this week through the mountains and around where the temps were varying from 50-100F so I was about to get an idea of how this intercooler behaves.

Putting the stock airbox in had definitely improved the temps while driving. When I'm WOT, the temp at the intake manifold drops significantly staying very close to the temps from my stock airbox.  They climb at the manifold after laying off the throttle, but nothing more than 4-8 degrees. Didn't really get a chance to see what kind of boost levels it reaches but seeing the temps drops has been more than enough to make me pleased.

Also, Mishimoto contacted me and stated the black is a stealth color that doesn't have the "M" on it. It's weird though seeing how almost every website that sells the J Line has a picture with the M on it. They did offer to send me a stencil, which I might do in the future with a matching pearl color as what my exterior coat is.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 07, 2020, 01:30:58 PM
Drove about 800 miles this week through the mountains and around where the temps were varying from 50-100F so I was about to get an idea of how this intercooler behaves.

Putting the stock airbox in had definitely improved the temps while driving. When I'm WOT, the temp at the intake manifold drops significantly staying very close to the temps from my stock airbox.  They climb at the manifold after laying off the throttle, but nothing more than 4-8 degrees. Didn't really get a chance to see what kind of boost levels it reaches but seeing the temps drops has been more than enough to make me pleased.

Also, Mishimoto contacted me and stated the black is a stealth color that doesn't have the "M" on it. It's weird though seeing how almost every website that sells the J Line has a picture with the M on it. They did offer to send me a stencil, which I might do in the future with a matching pearl color as what my exterior coat is.
So you're thinking stock airbox is a better option than something aftermarket? I can see how that would be the case...that box is truly closed off from the hot engine air....

I've got the AirAid setup and I really like it. Even with the foam edging, I'm certain it doesn't seal off 100%.

I'm wondering if making a cover for that AirAid setup could be the best of both worlds...it would be easy enough to make...

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Title: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 07, 2020, 05:16:31 PM
I was under the impression the intake I bought could fit a cover on it and realized after buying the wrong one that it was for an Edge. The  bigger and more expensive from aFe from what I had was completely sealed off and probably would have been the better option. The intake that ecopowerparts creates would probably be something to consider if it had a top on it.

I still would like to route another hole on the bottom under the filter to the fender to create an additional area for cooler air to pull from.

But yes I think the stock intake performs better with my setup since the air gets chilled off much quicker.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Macgyver on August 07, 2020, 05:32:39 PM
Drove about 800 miles this week through the mountains and around where the temps were varying from 50-100F so I was about to get an idea of how this intercooler behaves.

Putting the stock airbox in had definitely improved the temps while driving. When I'm WOT, the temp at the intake manifold drops significantly staying very close to the temps from my stock airbox.  They climb at the manifold after laying off the throttle, but nothing more than 4-8 degrees. Didn't really get a chance to see what kind of boost levels it reaches but seeing the temps drops has been more than enough to make me pleased.

Also, Mishimoto contacted me and stated the black is a stealth color that doesn't have the "M" on it. It's weird though seeing how almost every website that sells the J Line has a picture with the M on it. They did offer to send me a stencil, which I might do in the future with a matching pearl color as what my exterior coat is.
So you're thinking stock airbox is a better option than something aftermarket? I can see how that would be the case...that box is truly closed off from the hot engine air....

I've got the AirAid setup and I really like it. Even with the foam edging, I'm certain it doesn't seal off 100%.

I'm wondering if making a cover for that AirAid setup could be the best of both worlds...it would be easy enough to make...

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Someone in here did make a cover for the AirRaid. I think they tracked it too and posted numbers.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Macgyver on August 07, 2020, 05:37:47 PM
I did a quick search. I know there was a clear covered Air Raid in here somewhere.......

https://www.ecoboostperformanceforum.com/index.php?topic=9209.msg138707#msg138707

Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 07, 2020, 06:05:08 PM
Something like that would provide cooler air definitely. Iíd like to modify my stock intake for an additional air duct to see if that would help as well.

Iím also missing the duct piece under my bumper for the turbo closest to the firewall so Iím sure that would mitigate some of my heat from the engine bay.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 07, 2020, 06:06:39 PM
Something like that would provide cooler air definitely. Iíd like to modify my stock intake for an additional air duct to see if that would help as well.

Iím also missing the duct piece under my bumper for the turbo closest to the firewall so Iím sure that would mitigate some of my heat from the engine bay.
Yeah, I've been doing cardboard cutouts for a larger "squirrel catcher"myself, but haven't had much time to move past that stage...

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Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 11, 2020, 08:34:20 AM
Just checking in to see what updates you have for us. Any new developments? Anything you would do different?

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 11, 2020, 08:22:10 PM
I can say with certainty that the intercooler is definitely an improvement. I've been monitoring the temps at the intake, after the intercooler and at the manifold more this past week. The temperature after the intercooler will hover right around the air intake temp, except when in traffic and the intercooler temp cools down much quicker than at the air intake.  The manifold on the other hand, seems to be a bit cooler than with the stock intercooler but that sensor is in a naturally hot location anyway.

As for boost differences, it's been hard to tell since the outside temps have been around 100 lately compared to high 80's/ low 90s when I first installed it. I have no proof other than my butt dyno that it does feel like it pulls harder if I do a 0-100 run on it.

Mishimoto is sending a stencil of the "M" so I can paint it on myself. They don't sell the black one with any markings on it for the stealth look, even though every picture but their website shows otherise.
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 16, 2020, 09:28:22 PM
Just to put it out there, the stock intercooler weighs 7.40lbs on my scale and the Mishimoto is 18.7lbs according to the website. I didnít weigh the J-Line with any of the couplers or the aluminum extensions.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on August 16, 2020, 10:11:35 PM
Just to put it out there, the stock intercooler weighs 7.40lbs on my scale and the Mishimoto is 18.7lbs according to the website. I didnít weigh the J-Line with any of the couplers or the aluminum extensions.
Oh ok, but it did feel heavier than the stock one though huh? I think the benefits of the intercooler outweigh the weight gain though.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on August 16, 2020, 11:00:10 PM
Just to put it out there, the stock intercooler weighs 7.40lbs on my scale and the Mishimoto is 18.7lbs according to the website. I didnít weigh the J-Line with any of the couplers or the aluminum extensions.
Oh ok, but it did feel heavier than the stock one though huh? I think the benefits of the intercooler outweigh the weight gain though.

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Yeah it was noticeable when I took it out and put the Mishimoto in. One of the cons of a bar and plate IC but like you said the benefit of the cooling makes up for it.

I did pull on a 370z today while giving him the jump at a stop light. He looked puzzled afterwards.
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on September 05, 2020, 10:09:22 PM
So I painted my J Line two days ago and it makes me realize how restricted the front is for pushing air through the intercooler. I was looking into the raptor grille but it looks like the airflow is even worse. There is one company that sells a bottom and top billet grille but honestly seeing through it looks even worse than a stock one.

I also almost donít like the M for how italicized it is making it look off center. It was lined up by the top right and bottom left correctly too.

Bottom grille received a glossy black coat too.

One item I recommend using for the plastic trim along the bottom of the Explorers is the Wizardís Black Renew. Makes Motherís back to black look like a joke.

(https://uploads.tapatalk-cdn.com/20200906/f0f8237129105889d939c9ab8d6ccf59.jpg)

(https://uploads.tapatalk-cdn.com/20200906/dfcbdda5ccd0c15a74789ab11ef85279.jpg)
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on September 05, 2020, 10:17:00 PM
So I painted my J Line two days ago and it makes me realize how restricted the front is for pushing air through the intercooler. I was looking into the raptor grille but it looks like the airflow is even worse. There is one company that sells a bottom and top billet grille but honestly seeing through it looks even worse than a stock one.

I also almost donít like the M for how italicized it is making it look off center. It was lined up by the top right and bottom left correctly too.

Bottom grille received a glossy black coat too.

One item I recommend using for the plastic trim along the bottom of the Explorers is the Wizardís Black Renew. Makes Motherís back to black look like a joke.

(https://uploads.tapatalk-cdn.com/20200906/f0f8237129105889d939c9ab8d6ccf59.jpg)

(https://uploads.tapatalk-cdn.com/20200906/dfcbdda5ccd0c15a74789ab11ef85279.jpg)
Nice. I feel you on the airflow issue. I've been trying to visualize something that would look good but also functional. I absolutely hate those Raptor grilles, they look ridiculous on anything but a Raptor.  But you might be interested in the police interceptor grille. I was thinking about it but it would also need some cutting I think..

There are just no real options for the XSport, tbh.

Anyway, I would've left the IC raw aluminum. I like the look, like it means business with a mean looking aluminum intercooler in your face. There's also actually been some tests showing black intercoolers may not be as efficient as raw aluminum...I'll look for the link and pass it on.

But it's really cool what you've done and I am excited to get my version going as well. These things desperately need a more efficient IC.

EDIT: video link

https://youtu.be/z_mmmXTbLP0

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Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on September 05, 2020, 10:26:57 PM
I was going to go with the unpainted IC but I figured black was going to be the best look overall. At this point I can just hope a car wash that has a bit of a higher pressure than a normal one can take my paint off slowly without damaging the fins.

The stock XLT grille looks like it has holes in it which I wonder if it would be able to line up with the Sports where we could turn those holes into vents for the intercooler.

I will say I averaged 25.7MPG going to Pagosa Springs this weekend which was about a 410 mile round trip with elevation varying from 4,600-10,800ft and 7% grades. I would see the temp at the throttle body cooler than at the airbox quite often too which was noticeable climbing elevation. Had cruise control on mostly at 67-77mph as well with temps 80-95F ambient.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on September 05, 2020, 10:30:49 PM
I was going to go with the unpainted IC but I figured black was going to be the best look overall. At this point I can just hope a car wash that has a bit of a higher pressure than a normal one can take my paint off slowly without damaging the fins.

The stock XLT grille looks like it has holes in it which I wonder if it would be able to line up with the Sports where we could turn those holes into vents for the intercooler.

I will say I averaged 25.7MPG going to Pagosa Springs this weekend which was about a 410 mile round trip with elevation varying from 4,600-10,800ft and 7% grades. I would see the temp at the throttle body cooler than at the airbox quite often too which was noticeable climbing elevation. Had cruise control on mostly at 67-77mph as well with temps 80-95F ambient.
Awesome results. Need to do some data logging on a few particular parameters so you can find out how truly efficient it is.  Calculating Boost Air Density is a great way to compare apples to apples when doing mods and seeing how they effected performance even under different test conditions.

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Title: Re: Any Explorer Sport intercoolers available?
Post by: GotGrip? on October 02, 2020, 09:10:25 AM
There's also this for black intercoolers, black coolers are probably best for staging but less effective during while moving.


https://www.youtube.com/watch?v=f1QL9veQaNg&list=PLFmS619mhCpl9bxAOvbnCvz_xrIbvVHT6&index=103 (https://www.youtube.com/watch?v=f1QL9veQaNg&list=PLFmS619mhCpl9bxAOvbnCvz_xrIbvVHT6&index=103)
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on October 21, 2020, 10:16:17 AM
Looks like someone finally came to market with one.  Garrett cores are good quality cores, but it sure does require a lot of cutting of the core support.  I realize there isn't much real estate in this platform but it ma turn some buyers off.  Still, it's nice to finally see one being marketed...
https://ultimateperformancenm.com/shop/ols/products/13-19-ford-explorer-sport-intercooler
Title: Re: Any Explorer Sport intercoolers available?
Post by: xartic1 on October 21, 2020, 02:21:56 PM
Thatís quite a bit more than I cut out. Looks like making one from a Mishimoto J Line you have a 22Ē vs 24Ē core and 7.2Ē vs 8Ē height. So a small trade off in size but also $650 in savings.

Also curious how much more this IC weighs compared to my J line.
Title: Re: Any Explorer Sport intercoolers available?
Post by: Ecoboost_xsport on October 21, 2020, 08:20:52 PM
Yeah, I'm trying to find some data on the Mishimoto as far as flow data is, but its hard to find, but from a quality perspective, Mishimoto isn't even in the same league as Garrett. Not knocking your setup, nor do I have any ideas about the quality of this new kit, but I can appreciate that they went with a top-of-the-line brand that is proven on high end builds.  Mishimoto is marketed toward the entry-level, budget build area and works great there.


Would be an interesting comparison. That Garrett core holds about 15% more volume of air. Almost 100 cubic inches.


The question is CFM, though. Ratings for Mishimoto say up to 500hp, while Garret rates theirs at up to 600hp..


I smell a test! Lol...
Title: Re: Any Explorer Sport intercoolers available?
Post by: GotGrip? on December 22, 2020, 12:10:17 PM
Best flow rate is a vertical flow cooler, you might give up a little in IATs but you'll make more power with the amount of air that will push through.
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