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Mishimoto Build Thread: 2011-2014 Ford Mustang 5.0L Direct Fit Oil Cooler Kit

Old 02-17-2014, 08:57 AM
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Default Mishimoto Build Thread: 2011-2014 Ford Mustang 5.0L Direct Fit Oil Cooler Kit

Hi Mustangforums,

Our team is developing a unique oil cooler kit for the 2011-2014 Ford Mustang. We have decided to document the development process to provide an inside-look at what our team does on a daily basis to bring high quality cooling products to market!

Follow our engineering blog to learn about this project and other great insider knowledge regarding upcoming projects. Thanks for taking the time to check out our thread!

2011–2014 Ford Mustang GT Direct-Fit Oil Cooler Kit, Part 1: Introduction and Goals

There is so much to say about the Ford Mustang and its legendary history as a high-performance, tire-melting pony car. Ford has been constantly improving the chassis, engine, and body since the 1960s (minus a lapse in the mid-1970s … we forgive you, Ford), and the most recent vehicle is nothing short of fantastic. The Coyote 5.0L engine produces substantial power and is finding its way into a variety of vehicles as a great engine swap candidate. These days, it is refreshing to see something different than the ever-popular LS swap, not that I have anything against that. Ford has also constantly improved the chassis, creating a vehicle that will not only rip down the drag strip, but is also fairly capable through the corners. With the 2015 model on the way featuring an IRS, we can expect even better handling! The fifth-generation Mustang has become a common contender on the drag strip, autocross course, road course, and even the drift circuit. Its low curb weight compared to other modern muscle vehicles provides a unique advantage that enthusiasts can really appreciate.

With all this in mind, the Mustang was an easy choice for our group to develop a direct-fit oil cooler kit. The factory Mustang GT is not equipped with any form of liquid-to-air or air-to-air cooler that would help keep temperatures at bay. Is an oil cooler needed for street driving? This depends on your driving style. If you are terrorizing your neighborhood with 300 ft burnouts to get the tires properly warmed up for your commute, then possibly so. For most street driven vehicles, however, lacking an oil cooler will not be an issue. For those of us who enjoy utilizing the capabilities of our vehicles for track use, even if occasional, an oil cooler setup can certainly be beneficial. These benefits are not only short term, but will also help extend the life of your vehicle. When oil is overheated it begins to degrade rapidly, which results in a lower viscosity and a higher probability for engine wear and damage. The Mustang is a 3500 lb vehicle with a 420 hp V8, so things are going to get hot!

We first set out to see what was available for the Coyote. The current offerings are reasonably nice products, but we found a great deal of opportunity to create a better performing product with proven data and a price tag that is much easier to swallow. We know that many owners are upgrading to the Boss 302 liquid-to-liquid cooler. I am not going to knock this upgrade, as this will certainly provide the benefits of a quicker oil warm-up and will help reduce temperatures overall. It’s a great system that is relatively inexpensive and easy to install. The only problem is that liquid-to-liquid cooling systems often have limitations. For those pushing their cars hard, a liquid-to-air cooler is what you want for maximum efficiency. We located a few products on the market that feature some high-quality components. The only snafu was the absurd price tags. No one wants to have that “Sorry I spent our vacation money on an oil cooler” conversation with a significant other. Knowing that we could develop a better product for a more manageable price, we set out to develop a list of goals for the project.

Goals
1. Must be a direct-fit unit requiring no permanent vehicle modification
2. Must have proven data of temperature reduction
3. Must include all components for installation
4. Must be reasonably priced

For our team of skilled engineers, this project would be a walk in the park. So we set out to locate a test-fit vehicle to bring in for some initial design work. After some searching we were able to find this fantastic 2012 model that would fit the bill perfectly.



Check back next time for design, fabrication, and testing of our first prototype!

Thanks

Last edited by Mishimoto; 02-25-2014 at 04:40 PM.
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Old 02-19-2014, 02:14 PM
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2011–2014 Ford Mustang GT Direct-Fit Oil Cooler Kit, Part 2: Initial Prototype Design and Testing

With our test vehicle in the shop, our team set to work planning our attack on this Mustang. Our primary goal was to achieve significant temperature decreases. We got this beast in the air and inspected our challenges with the oil sandwich plate location. Our standard and thermostatic sandwich plates use either a ¾-16 or M20 sandwich plate adapter. This component secures the sandwich plate between the block and the oil filter.


Oil sandwich plate exploded


Oil sandwich plate assembled

The images above show the orientation of the sandwich plate and filter on the engine. Oil passes through the filter, then into the sandwich plate. The two ports on the plate will have lines feeding the cooler. Once through the cooler the oil will return to the sandwich plate via the second port and back into the engine. This is a common practice for adding an oil cooler to a vehicle that is not equipped with one from the factory.

As described above our current offerings are for ¾-16 and M20 threads, but the Mustang features an M22 filter thread. This means we would need a new sandwich plate! It is not all bad news on the sandwich plate front. This vehicle has a fair amount of space in the engine bay, so we could utilize one of our thermostatic sandwich plates, and line routing would be fairly simple. Check out what we are dealing with!


Oil filter location


Oil filter location


Oil filter location

Once we were satisfied with the plan to create a new sandwich plate, we compared the pros and cons of the thermostatic vs. non thermostatic plates. A thermostatic sandwich plate works similarly to the coolant thermostat in your vehicle. Once a specific temperature is reached, the thermostat opens and allows oil to flow through the cooler. So why would someone want this? Obviously everyone is aware that hot oil temperatures can damage your engine. Oil degradation is a serious problem. That being said, cold oil temperatures are also a potential hazard to your Coyote. This is why many choose to allow the vehicle to warm up properly before laying the pedal to the floor. Mishimoto currently offers an optional thermostatic sandwich plate with a majority of our direct fit oil cooler kits. This option is especially recommended for those using their vehicle as a daily driver or for those living in cooler climates.

After a heated debate, our team decided that this kit must include a thermostatic plate. Our goal is to protect your engine. Including the thermostatic plate would allow full regulation of oil temperatures. Next, it was time to select a location for the cooler.

The front bumper or grille area was targeted because of the fresh, cool airflow.


Bumper removal


Bumper removed


Bumper removed

So this is what we are left with, shown above. The huge amount of open space provides room for our team to get creative with the design of this kit. The design would be very different than the ones for smaller vehicles, where every inch matters.

For our first design, the plan was to mount the cooler in the upper portion of the grille. This location looked like a great spot for airflow, and we a few available mounting points that would work very well.

Steve, the lead engineer for this project, began fabricating the brackets.


Bracket design 1


Brackets on cooler

These two brackets would suspend the cooler from mounting points on the radiator support. Two additional brackets would support the base of the cooler to points on the bumper support. We would be using strong material that would have no problem supporting the cooler.

These brackets were then fitted to our Mishimoto 25-row stacked plate oil cooler and installed in the vehicle. This is currently our largest oil cooler option and would provide greater heat transfer than our 10-row and 19-row coolers. The larger size also provides increased surface area for airflow and increased capacity. Both these benefits will result in lower fluid temperatures. Check out the mounted upper brackets!


Version 1 upper brackets mounted


Version 1 upper brackets mounted

The images above show the location of the brackets and the cooler in relation to the upper radiator support. We need to keep in mind the routing of our oil lines when placing the cooler.


Version 1 upper brackets mounted

Once the upper brackets were installed and solidified, we needed to link the base of the cooler to the bumper support. Without lower supports, our team was concerned about the cooler making contact with the A/C condenser.


Version 1 passenger side lower bracket mounted


Version 1 lower brackets installed

Once the four brackets were installed, the cooler was adequately supported and cleared all factory components in this space. The clearance to the condenser would provide some room for flex. Check out some close-up shots below.


Version 1 brackets and cooler installed showing clearance to condenser


Version 1 brackets and cooler installed from below

So with this design in place we needed to slap some testing equipment on and get this pony on the street for some data collection. We use PLX devices for capturing live information, and we also have the ability to record and log our sensors. For this particular test we will be collecting oil temperature and pressure.


PLX sensors installed


PLX sensors installed

The multi-colored sleeves house the sensor harnesses that run into the cabin of the vehicle. These wires are connected to our PLX devices box which then displays information on our laptop.


Mishimoto PLX box


Gathering live data

Once all our testing equipment was set, we hit the road to collect some information. Our team drove on the highway for several miles at 65 mph. Special attention was given to vehicles in front of the Mustang to ensure that proper airflow was reaching the front of the car. After completing the test drive, we returned to the shop, removed the Mishimoto oil cooler kit, and installed all the stock components. We then collected baseline temperature information to use as a comparison with our design. We repeated the driving conditions performed in the first test drive to ensure that the comparison was as accurate as possible. All testing was completed in 85-to-90 degree weather during the late summer here in Delaware.

Analysis of the data revealed that the average temperature drops around 20°F, which was a nice decrease from the factory setup without any cooler. We were also surprised to see that oil temperatures were around 220 degrees without any cooler installed. With just normal highway driving, 220°F is rather high; a day on the track or stressful driving might increase that significantly. Any temperature over 240 to 250 degrees is working its way into the danger zone of reduced oil viscosity. At this point your oil thins and becomes less efficient at lubrication. This is not a problem you want to have.

With testing complete our engineers evaluated our design and looked for ways to improve efficiency. Twenty-degree temperature drops are great, but we felt that we could improve efficiency even further. Our next task was to assess airflow. Our current core position was in the upper grille area, and we were curious to see if there were differences in airflow between this location and the lower bumper opening. We tested airflow using our anemometer and found that we could improve flow by moving the cooler to the bumper location.


Anemometer

The anemometer is essentially a small windmill-like device that accurately measures wind speed. With this information, we needed to revise or reconstruct our bracketing system to move the cooler to the new location.

Check back for the next update with our new cooler mounting setup and testing!

Last edited by Mishimoto; 02-24-2014 at 09:02 AM.
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Old 02-24-2014, 08:53 AM
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Hey Guys,

This kit is nearing release! Check out the final portion of the build below!

2011–2014 Ford Mustang GT Direct-Fit Oil Cooler Kit, Part 3: Prototype 2 Design and Testing

With one round of successful development and data collection complete, our engineers set out to improve upon the first design. After gathering airflow data for different bumper locations, they decided to move the cooler to the lower bumper opening as opposed to the grille area. Instead of modifying the existing brackets, our team developed a new bracket that would suspend the cooler and attach directly to the bumper support. This new bracket not only brought the cooler to a better location, but it also provided a more rigid, robust mounting system for the large 25-row cooler. This also eliminated the need for four brackets; instead just one cross bar would be needed. Check out a few shots of the prototype!


Oil cooler bracket prototype 2


Oil cooler bracket prototype 2

Once fabricated, the team was very pleased with this new design. The cooler placement was close to the front bumper but would not require any cutting or trimming. The bracket also utilizes existing mounting points on the front bumper support so no drilling would be needed. This is a true bolt-on unit.


Oil cooler clearance to bumper

Check out a few shots with the bumper installed! We performed the testing with our powder-coated black unit. This kit is also available with a silver cooler for those who prefer a more visible setup.


Oil cooler fully installed


Oil cooler with bumper installed

Once we were satisfied with the prototype, we reinstalled our PLX devices and again took to the highway for data collection. Although this test was completed a day later, temperatures were nearly identical.


Oil cooler fully installed with lines

All our direct-fit kits include premade stainless steel braided oil lines that include –AN fittings. These lines are extremely durable and are not easily ruptured. The stainless sheathing can be rather abrasive, and if not handled and routed properly, other engine components could be damaged from rubbing.


Full garage

Back to the data collection! The new location enabled reduced temperatures to 185°F! The improved airflow had a significant impact on average temperatures. This new location resulted in a 35°F drop over the OEM setup in normal conditions. This reduction in temperature will be compounded during track or aggressive driving.


Comparison of stock Mustang to Mustang with Mishimoto oil cooler kit

With successful test results, the project was essentially finished, and our team began constructing models and drawings of the components for mass production. Check out this neat rendering of the oil cooler bracket!


Mishimoto oil cooler bracket rendering

Now that the project has reached completion, let’s check back with our goal list and review the success of this project.

Goals

1. Must be a direct fit unit requiring no permanent vehicle modification

Result: This kit utilizes existing mounting locations and requires no cutting, drilling, or trimming.

2. Must have proven data of temperature reduction

Result: Our proven kit reduces temperatures by 35°F

3. Must include all components for installation

Result: This is a bolt-on oil cooler kit and includes all necessary components for easy installation.

4. Must be reasonably priced

Result: This kit will be priced far below any products currently on the market.

So, I’m sure you’re wondering what this kit will include and how much it will cost. The kit will include the following components:
  • Direct-fit oil cooler bracket
  • 25-row stacked plate oil cooler in black or silver
  • M22 thermostatic sandwich plate and stainless steel adapter
  • Premade stainless steel oil lines
  • Oil cooler installation hardware

This kit will be priced to fit the budgets for both street and track vehicles. At this time, we intend to offer this kit for less than $600, through any of our vendors. It is hard to put a price on engine longevity, and this is a fantastic value for a bolt-on, proven oil cooler kit.

Thanks for following along with the R&D process for the 2011–2014 Ford Mustang oil cooler kit. We are anticipating a release date very soon! Feel free to follow up with any questions or comments, I would be happy to answer them.

Thanks

This build and many more can be found on our new engineering blog! Check it out!
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Old 02-24-2014, 09:16 AM
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Matt's 95 Stang
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Once you guys actually make a radiator that wont leak get back to me.
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Old 02-25-2014, 04:43 PM
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Originally Posted by Matt's 95 Stang
Once you guys actually make a radiator that wont leak get back to me.
Our company produces a substantial amount of radiators each year and we are always proud to report a defect rate well below industry standard. Product defects are a part of any form of manufacturing process and we work hard to reduce this rate by improving product materials and our quality control process. You may be referring to our SN95 radiator which was susceptible to an inherent chassis flex issue. Instead of continuing with our existing product or adding band-aids, we redesigned the radiator with a patent-pending bracketing system that isolates the radiator from the chassis. If you do recieve a defective unit, our no questions asked lifetime warranty will ensure you get a replacement quickly and without hassle.

With that said, this thread is in regards to our new oil cooler and I would be happy to answer any additional questions!
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Old 02-25-2014, 05:01 PM
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Fantastic information, another reason why we trust and sell Mishimoto parts! Great write up!
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Old 02-26-2014, 06:32 AM
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Any projected launch date? Or too early to say? The data looks great with some big improvements over stock, nice work!
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Old 02-26-2014, 08:19 AM
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Originally Posted by ModBargains
Fantastic information, another reason why we trust and sell Mishimoto parts! Great write up!
Thanks!

Originally Posted by BrazenStang
Any projected launch date? Or too early to say? The data looks great with some big improvements over stock, nice work!
Thank you very much! A majority of the project and testing were completed a few months ago. We are expecting a release either later this week or early next week. Once the release is official, I will make a post in this thread with all the product information!

Thanks!
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Old 03-03-2014, 04:24 PM
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A few of the key components for this kit! Check it out.


Last edited by Mishimoto; 03-03-2014 at 04:31 PM.
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Old 03-07-2014, 09:59 AM
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This kit has officially been released and is now available for purchase! Check out the product details and images below!

Ford Mustang 5.0L Oil Cooler Kit, 2011-2014

Product Specs
  • Direct-fit for the 2011–2014 Ford Mustang 5.0L
  • Reduces oil temperatures by 35°F
  • Application-specific mounting bracket
  • Premade stainless steel braded oil lines with durable -AN fittings
  • Billet aluminum thermostatic oil sandwich plate
  • 25-row stacked-plate oil cooler for optimal fluid temperature reduction
  • Cooler available in either Sleek Silver or Stealth Black
  • Increases oil capacity by 0.75 qt
  • Mishimoto Lifetime Warranty

Tech Specs










Feel free to follow up with any questions!
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