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This is still against the radiator on the back side? This wouldnt let much air flow go over the fins and you would have to match the radiator fins also or you would even have less air flow. No matter how big the IC is if you dont have air flow its going to get hot. I think this is why the manufacturer made a tin core cause its also sandwich to the radiator. At this point water/meth injection would be the best solution to keep intake air temp under control. Just my two cents.
We all have our "two cents". What you are saying is partially correct but the same on every single car ever produced and the theory of it "not working" is incorrect. You can use meth/water injection if you like, I've found them to be a hassle and extremely unreliable, even more so on something that is going to stay in boost when you are towing, the tank will drain quickly.
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Any word on how long till the turbo and exhaust is available? I’ll probably do all 3 at the same time
The exhaust samples should be here today, we have to test fit the bending and give approval to bend the remainder. The industry is so screwed up right now it's hard to say when we will hit the bend schedule again. Good thing is two test pieces are coming. The intercooler, we have cores here now, waiting on the tanks to be laser cut and the inlet/outlets to be CNC'd. I'd think those will be less than two weeks.
 

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The (hopefully upcoming) BEV Maverick will solve this issue completely. Jk jk

I have limited knowledge on this- why would anyone need this in their Maverick over what Ford has engineered and made stock? How much can you really improve an entry level vehicle like a Maverick? what is it really improving?
 

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The (hopefully upcoming) BEV Maverick will solve this issue completely. Jk jk

I have limited knowledge on this- why would anyone need this in their Maverick over what Ford has engineered and made stock? How much can you really improve an entry level vehicle like a Maverick? what is it really improving?
These were made to a price point, and various components will reflect this. Im sure this intercooler meets (barely) everything ford designed to, and is almost surely compromised to fit the price point.

This is what the aftermarket is for, finding all the deficiencies from the factory.

Replacing intercoolers on any turbo charged vehicle is common place now, always room for improvment!

It may not make sure big increases by itself, but when a larger turbo is added, it will have huge gains over the stock unit. As outlined here, the intercooler is a bottle neck for power.
 

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The (hopefully upcoming) BEV Maverick will solve this issue completely. Jk jk

I have limited knowledge on this- why would anyone need this in their Maverick over what Ford has engineered and made stock? How much can you really improve an entry level vehicle like a Maverick? what is it really improving?
From being in the Subaru WRX world I'll tell you that some cars make great platforms to build on. True they are good as they stand... but once they get in the right hands the cars become a whole different beast. These Mavericks are great trucks as they are. I think we will see some real magic happen as the months progress. Ford built these to meet a price point but they left a lot of room to build on. There is a lot to say for a solid body as a base... not all cars are that way.
 
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ntercooler upgrade considered something that will affect warranty?
I'd say if you change the tune and the engine goes bang then yes, no warranty.

What is the stock PSI on the Mav (under full boost)? I seriously doubt Ford undersized this on a stock mav....But, hey, mistakes do happen.

U chip, U buy.
 

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This core isn’t too big? Too much intercooler can be a hinderance too.
Usually bigger is better. Less pressure drop if it flows better so it runs cooler and more fin area so also cooler, and cooler is better. In theory it might have a tinsy bit extra lag since there's more volume to pressurize between the turbo and engine, but I think that only happens to a noticeable extent when people use exotic locations with lots of or too big of pipes rather than just thicker intercoolers.
Out of curiosity is a intercooler upgrade considered something that will affect warranty? I've never had a vehicle worth enough to have a warranty on :ROFLMAO:.
Legally, they have the burden of proof of showing that the aftermarket part is causing the issue. Practically, a tech just has to say "its my professional opinion that the aftermarket intercooler can cause bla bla bla" and they won't even investigate further, and you'll be SOL because Ford has more lawyers than you do. That said, while a dealership tech could BS that it could be related to some problem with the engine or transmission, that's about it, so if your headlight goes out or you have a clunk in the rear suspension, its not like they can remotely get away with blaming an intercooler and invalidate your entire car's warranty.

Usually though, you only bother with intercooler upgrades when you're running more boost than stock, and the dealer can see that unless you use a piggyback, so that would be the part that would affect the powertrain warranty (unless Ford comes out with their own tune under warranty which I believe they have for the Ranger).
Do you have an image of the stock intercooler? I'm just curious to know what it looks like without a bumper in the way...
Mr Boom took his truck half apart on his channel:
Screenshot 2022-01-13 005833.jpg
 

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I do not, didn't take any getting it apart and now the stock one is cut up, we had to send the tanks to the machine shop.
I am curious which model TRIM were you working on in these photos? I have the AWD version w 4K tow ordered (1st Ed) - which has a larger cooling system due to Tow capabilities; my hope is that you are NOT referring to this system? And... if you are not commenting in regard to that system are you able to OPINE on the larger system used in First Ed 4KTow package?
 
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I'd say if you change the tune and the engine goes bang then yes, no warranty.

What is the stock PSI on the Mav (under full boost)? I seriously doubt Ford undersized this on a stock mav....But, hey, mistakes do happen.

U chip, U buy.
Stock boost is about 16 psi and its undersized and sucks from the start, as does every factory intercooler on every car I've ever seen.
 
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Usually bigger is better. Less pressure drop if it flows better so it runs cooler and more fin area so also cooler, and cooler is better. In theory it might have a tinsy bit extra lag since there's more volume to pressurize between the turbo and engine, but I think that only happens to a noticeable extent when people use exotic locations with lots of or too big of pipes rather than just thicker intercoolers.

Legally, they have the burden of proof of showing that the aftermarket part is causing the issue. Practically, a tech just has to say "its my professional opinion that the aftermarket intercooler can cause bla bla bla" and they won't even investigate further, and you'll be SOL because Ford has more lawyers than you do. That said, while a dealership tech could BS that it could be related to some problem with the engine or transmission, that's about it, so if your headlight goes out or you have a clunk in the rear suspension, its not like they can remotely get away with blaming an intercooler and invalidate your entire car's warranty.

Usually though, you only bother with intercooler upgrades when you're running more boost than stock, and the dealer can see that unless you use a piggyback, so that would be the part that would affect the powertrain warranty (unless Ford comes out with their own tune under warranty which I believe they have for the Ranger).

Mr Boom took his truck half apart on his channel:
Screenshot 2022-01-13 005833.jpg
Really good answers and comments! Thanks.
 
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