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Focus On ReSpiration: Mishimoto Ford Focus RS Performance Intake R&D

This is a discussion on Focus On ReSpiration: Mishimoto Ford Focus RS Performance Intake R&D within the Focus RS Performance forums, part of the Focus RS Garage category; Hey everyone The time is now...we are now ready to officially launch our presale! During this period, you can get our intake at a great ...

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Thread: Focus On ReSpiration: Mishimoto Ford Focus RS Performance Intake R&D

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    Focus On ReSpiration: Mishimoto Ford Focus RS Performance Intake R&D - NOW IN PRESALE

    Hey everyone

    The time is now...we are now ready to officially launch our presale! During this period, you can get our intake at a great discount before the final production kits hit the warehouse and the market.
    Please check out the details below and please let us know if you have any questions!

    PreSale Link

    Expected Release: Early February 2017

    Be sure to take a look at our development thread below!

    ReSpiration Focal Point: 2016+ Ford Focus RS Performance Intake R&D, Part 1: Stock Intake

    Finally!! Ford has teased us with the prospect of an all-wheel-drive (AWD) Focus RS for the US since the early 2000’s. Now, in 2016, it is finally here and in our garage. This is pretty groundbreaking considering that no Ford with an RS badge ever made its way to American soil, and they were not hot-hatches to ignore. The label had particularly dominated the rally world. Who can forget the infamous Escort RS Cosworth rally car with its countless podium finishes or the Focus RS WRC that won back-to-back manufacturer titles in 2006 and 2007? We at Mishimoto haven’t, and we’re glad to be reveling in all the mechanical glory that is Ford’s newest, AWD, turbocharged hot hatch.

    Besides Ford providing us with a vehicle name that carries endless puns and name plays, this RS is packed with goodies, making it hard to pick an area to focus on because there are so many awesome features (I promise, that will be the only pun.). Although this RS shares its heart with the Mustang EcoBoost, it does have slightly more power, boasting a hearty 350 hp engine. And how about that drift mode feature? There is a lot of information I can get into here, so for more, check out our vehicle review!







    This stock intake is actually not all that unfamiliar to us. We have designed an intake for the Focus ST as well, (read that here) and it gave us some promising numbers. However, these kits will not be directly interchangeable. Let’s take a look at this new RS intake!







    The airbox has a lot of features similar to the ST airbox; it even uses the intake air temperature (IAT) sensor that the 2015+ ST models use. (The 2013+ ST models use a mass airflow sensor.). Ford has also retained the two tubes coming out of the airbox and that attach to the front grille. Of course, we will opt to keep this design feature in our prototype.





    When it comes to the intake tube, it is actually a slightly more complex piece. The fitment space is very tight, and the small attachments on the tube will make it a challenging design. An aspect that stands out from our intake projects is the omission of a sound induction tube. These tubes direct more engine sound into the cabin of the vehicle by attaching directly to the intake and connecting to the firewall. The RS doesn’t have this tube located on the intake; it is rather directly attached to the hot side intercooler pipe!

    Another key difference is the shape of the intake tube, compared to the ST. The tube for the ST is flatter compared to the more cylindrical design of the RS. Check below for a quick comparison.






    What's Next?



    We have a clear view of where we want to go with the prototype design. We will report back with our plan of attack soon, so stay tuned! Thanks for reading!
    Last edited by Mishimoto; 12-22-2016 at 09:58 AM.

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    Love the detailed threads!
    SuperDave42 likes this.
    2016 Ford Focus RS

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    @Mishimoto can you focus on the RDU, a cooler maybe?


    Sent from my iPad using Tapatalk
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    Quote Originally Posted by Zach99 View Post
    @Mishimoto can you focus on the RDU, a cooler maybe?


    Sent from my iPad using Tapatalk

    I say keep increasing power until that thing pops. We already have a good idea of what the rest of the drivetrains potential is, but that RDU is a complete unknown.


    One of my favorite quotes from Hunter S. Thompson regarding the edge:

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    2016 Ford Focus RS (Frozen White, Base) STATUS: SHE'S FINALLY MINE!!!!
    Ordered: 10/12/15 ~ Selected: 1/21/16 ~ Built: 3/14/16 ~ Shipped: 4/26/16 ~ Delivered:6/16/16

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    Very cool stuff. Clever stuff for sure. Newer monufacturing processes help keep cost way down so ford can spend a little more time Making the car more efficient.
    SuperDave42 likes this.
    08 STI Forged built HMS stage 3 short lock, HTA68 td06 SL2 8cm turbo, Cobb cai with air box, perrin Inlet hose, Radium fuelrails, tgv delet, Tomei equal length headers, Tomei uppipe, 3" Perrin downpipe with two cats, 3" vibrant exhaust, Cobb ID1000cc injectors, Cobb flex fuel kit, Cobb AP, Radium catch can, Radium FPR, AEM fuelpump, ACT clutch, misimoto alum radiator, Perrin pully, Perrin pars, Perrin rear 22mm swaybar, super pro diff bushings, whiteline steering rack bushings,

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    Will be following this, and how detrimental the tune is for it. Sure, most intakes today require tunes to get the power, but many require a tune to not run dangerously lean.
    SuperDave42 likes this.

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    Quote Originally Posted by The Dr View Post
    Will be following this, and how detrimental the tune is for it. Sure, most intakes today require tunes to get the power, but many require a tune to not run dangerously lean.
    No worry of running lean. The computer will correct especially being a MAP based system. On a MAF vehicle you can get turbulence by the MAF sensor and obscure readings. A tune will be needed to gain power as the vehicle will learn down and adjust accordingly to go to stock TQ targets for power.
    SuperDave42 likes this.

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    Quote Originally Posted by Slider View Post
    Love the detailed threads!
    Thanks!

    Quote Originally Posted by Zach99 View Post
    @Mishimoto can you focus on the RDU, a cooler maybe?


    Sent from my iPad using Tapatalk
    We are indeed aware of the issues people have been having with the rear differential and how hot it can get. A cooler is certainly something that could help and it is something that we will try to look into!

    Quote Originally Posted by The Dr View Post
    Will be following this, and how detrimental the tune is for it. Sure, most intakes today require tunes to get the power, but many require a tune to not run dangerously lean.
    A top priority for us to be sure that this intake will run safely on a stock tune. Also, keep in mind that a byproduct of making power with an intake is running slightly leaner. More air usually equates to more power! We will carefully monitor AFR's here to be sure that the intake will be safe enough and will cause no harm to the motor.
    Ecobeast and SuperDave42 like this.

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    ReSpiration Focal Point: 2016+ Ford Focus RS Performance Intake R&D, Part 2: Something’s Rustling Up


    The RS has gotten a lot of attention the past few weeks, especially with the ball in our court. Need I remind you of our awesome stock dyno clip?




    But somethin’s-a-brewin with one of our most recent projects, the performance intake we are developing for this hot hatch. We mentioned earlier that the development of this intake kit is not completely uncharted territory, considering that we made one for the 2013-2014 Focus ST. However, as we dived further into this project, we uncovered the true complexities of this design compared with our ST intake kit.

    Intake Construction

    What exactly makes this intake pipe so much more complex? It’s simple: More attachments and brackets need to be added so that the fit will be accurate. Not only have the number of these attachments increased, but also the orientation of these pieces are not easy to accommodate. There will be bends with relatively tight tolerances, and these measurements must be exact. Difficult? Yes. Impossible? Not at all!

    First, we needed to decide how the pipe should be routed around the engine bay with all the attachments and brackets properly placed. Almost immediately, we knew we’d want to use a silicone piece that attaches to the turbo behind the motor, but for the mockup, this part was printed.





    Now it comes down to the long piping section. Once the initial mockup of the piping was completed, it was up to our lead fabricator, Mike, to get the pipe welded together and mocked up on the car.





    Once this step was completed, it was time to make those brackets and attachments that would hold the intake pipe properly in place. This part of the project is actually very interesting because of how we developed these small components using our waterjet. Check out a shot of it in action below!



    When the water settles, you get the resulting cutouts.





    This process is cool because it shaves off time from the R&D process. Before our waterjet days, these particularly small yet complex pieces would have been painstakingly cut by using a myriad of different drill bits, tools, files, etc. With no waterjet, this part of the project would have taken about five hours to complete. Now, however, we upload the exact specs of these pieces to the waterjet computer, and it simply cuts them using high-pressure water mixed with an abrasive material. Total time taken? About 30 minutes — the longest part of that being the machine setup, which generally takes around 25 minutes. Time is money, so, yeah, we’ll take the latter.

    In the images below, the parts have been properly bent to their correct shapes. Take a look at the fitment.







    Next up was the airbox, which is pretty similar to the ST box, but Ford made a statement with its honeycomb lid design. It is certainly one of the more visually pleasing stock intake airboxes we have seen here at our R&D facility. Getting air to the filter is important, so we will be using both of the fresh air inlet scoops that route into the stock airbox with the OEM-supplied inlet tubes.





    These airboxes appear to be somewhat similar, but they are actually very different with minor, yet significant dimension disparities in the digital 3D design space. One immediately noticeable difference is the prototype airbox lid; the ST lid is completely flat, whereas our RS lid has some bends that create a bit of a curve.

    So what does the entire prototype now look like? See for yourself!



    Above, you can also see one last addition, which is the fitting for the IAT sensor. It has been glued on for now using a highly adhesive epoxy. This prototype is not a particularly good looker right now, but that’s all part of the R&D process! Next up, dyno time — let’s see if we can get a tune out of this trombone!

    Thanks for reading!
    j0shm1lls, DBags18, Slider and 6 others like this.

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    Excited to see how this turns out! I am looking for a solid intake to pick up.

    Why are you guys designing a closed-airbox design over an open box? Just curious.
    SuperDave42 likes this.
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