Pipercross Induction Kit Ford Ranger Raptor V6 Ecoboost

Pipercross Ford Ranger Raptor Intake System
The Pipercross Intake System has been designed and engineered to directly replace the OEM airbox and integrated intake plumbing on the Ford Ranger Raptor fitted with the 3.0 V6 EcoBoost engine.

KEY FEATURES

• Large filter heatshield including lid featuring:
o Significantly larger partitioned intake volume vs. OE closed airboxes
o OE grommet plus chassis hard-point mounting system
o Vibration-damping edge trim to isolate Pipercross & OE parts
o Full cover heatshield with provision for OE cold air feed
• Bespoke Pipercross conical air filters utilising market-leading foam filtration media
• Twin filter system that increases filtration surface area 36.09% over typical foam panel filters
• Powder coated, CNC mandrel-bent aluminium intake tubing with:
o Consistent internal diameters to eliminate OE flow-destabilising clearance indents
o CNC-machined AIT sensor provisions
o Integrated mounting brackets
• Step-matched, thick-walled silicone hoses for optimal internal airflow characteristics, proper engine movement decoupling and long-term durability
• Stainless steel hardware for long-term corrosion protection
• Designed, prototyped and iteratively refined using latest 3D scanning and CAD technology
• Testing validation
o Flow – Final design flow tested to confirm 234% maximum, 192% average airflow restriction decrease vs. Full OE intake system
 824 vs. 926 maximum CFM airflow capability (Full OE vs. Full Pipercross Intake)

OEM INTAKE ASSESSMENT
The OEM intake system on the 3.0 V6 Ecoboost engine adequately supports the Raptor in most scenarios, when the engine is operating with OE programming. However, aftermarket engine tuning (even conservative tuning) increases boost (and subsequent turbocharger air demand) enough that the OE intake components begin to limit performance of the engine, even in typical driving scenarios.

The Pipercross engineering team identified the OE intake filtration media type/total surface area, OE airbox and the airbox-integrated plumbing as areas of potential system performance improvement. Filtration media/surface area was to be improved via custom straight walled, foam-based air filters produced in-house at Pipercross. The airbox and the respective plumbing were to be partially replaced with aluminium heatshield and hard pipe assemblies that utilise the OE fresh-air ducting, while isolating this fresh air from ambient engine heat. All Pipercross components were to be maximised (filter size, partitioned heatshield space, hard pipe/hose diameter) for the available engine volume, without compromising clearance standards required for the long-term durability of the kit.

CONICAL AIR FILTERS
The heart of the Pipercross intake kit are the Pipercross straight walled air filters. These filters feature Pipercross’ time-tested and proven air filter construction methods, to achieve the targeted airflow performance of the kit while maintaining the airflow headroom to support significant future tuning packages/hardware upgrades. The bespoke Pipercross foam mesh blend strikes the perfect balance between increased flow and air filtration, while the coated mesh and formed rubber neck bases draw from decades of successful in-house Pipercross filter manufacturing. The utilisation of larger surface area, straight walled filters (each dedicated to a single turbocharger to maintain the OE configuration) increase filtration surface area 36.09% over typical panel filter inserts, and feature 90mm (3.5”) inner diameter outlets. These filters serve as the foundation for the performance increase offered by the Pipercross intake kit.

HEATSHIELD
The Pipercross heatshield were painstakingly designed to maximise the shielded volume within the Ranger Raptors engine bay, thus maximising the performance of the Pipercross air filters. The heatshield is tailored to the upper and lower OE fresh-air ducting, shaping airflow from the OE feeds connected to the forward heat exchanger cavity. In addition to utilising the lower ducting, the Pipercross part fully shields the filters from ambient engine heat, with centre-facing dividing walls that run tight to the vehicle frame and arch. The Pipercross component is CNC laser cut from corrosion-resistant 2mm aluminium sheet and powder coated for additional corrosion resistance/aesthetic appeal. To improve protection further, a lid to fully encapsulate the filters was added. Designed to sit snuggly around the heatshield and body work and enclose the OE upper cold air inlet section. The heatshield makes use of the OE vibration-damping chassis mounts, while also adding several fixed mounting points (via additional bolt-on brackets) for stability and long-term kit durability. To further assure the long-term durability of the Pipercross part, hybrid EPDM edging trim is used to isolate the heatshields from direct contact with any other components to prevent any vibration-related part failures.

HARD PIPES
The Pipercross Ranger Raptor hard pipe assemblies compliment the benefits offered by the air filters and heatshield assemblies, rounding out the overall performance capabilities of the Pipercross kit. Both hard pipe assemblies are constructed of 90mm (3.5”) outer diameter aluminium tubing that has been CNC-mandrel-bent, for a consistent cross-sectional inner diameter throughout each assembly (vs. welded sections that can create flow-destabilizing internal swarf areas). Temperature sensor placement was also carefully considered on the pipe assembly, with a CNC-machined sensor boss placed in almost identical locations to the OE plumbing (to ensure consistent and accurate sensor readings with the Pipercross kit installed). Both assemblies also feature brackets designed to accept vibration-isolating mounts, to eliminate the potential of part failure due to long-term weld/tubing fatigue loading. Each assembly is powder coated to stringent specifications, for additional corrosion resistance and aesthetic appeal without any internal bore/boss overcoating.

DETAILS
The subtle details of the Pipercross Intake Kit are what elevate it beyond the competition. The silicone hose features a smooth internal bore, flow-matched coupling transitions and 5-ply wall construction; yielding just the right amount of compliance without any of the airflow destabilization associated with typical, unmatched silicone hose connections. The Pipercross heatshield utilises the lower OE vibration-damping airbox chassis mounts, in addition to fixed mounting points (via the bolt-on brackets) for part stability and trouble-free operation throughout the life of the vehicle. All stainless-steel hardware is provided to ensure corrosion, oil and other adverse engine bay environmental factors have no effect on the Pipercross kit’s function or aesthetic – no matter how hard the vehicle is driven.

RESEARCH AND DEVELOPMENT
All Pipercross products are designed in-house, utilising the latest 3D-printing, 3D-scanning, CAD, CFD, airflow testing and performance testing product development technologies. The Pipercross Ranger Raptor Intake Kit saw several design stages/iterations, to integrate the largest air filters, shielded engine bay volume, hard pipe assemblies and hose possible while maintaining required part clearances. Bench airflow testing was conducted on the full OEM intake system and multiple Pipercross prototype intake design iterations, using Pipercross’ in-house, custom designed and built airflow test apparatus inside a controlled environment.

AIRFLOW TESTING DATA
Both the OE and final Pipercross intake configurations were tested on Pipercross’ in-house, custom built stationary airflow test apparatus. To develop an initial airflow baseline, the OE intake system was tested, with the left-hand and right-hand plumbing connected via a custom 3D printed inlet to their maximum airflow values. The complete intake system (including the airbox and panel filter) up to the turbocharger was tested. Of note from this testing round was the maximum airflow value that the OE component could support at 824 CFM, however the restriction was high. Both the LH and RH side of the Pipercross intake were then tested in the same manner. The table and graphs below summarize the results of this testing, confirming the performance benefit of Pipercross intake components and their vastly increased airflow capabilities. Again, the maximum airflow values of the Pipercross components were notable, with the kit supporting up to 926 CFM (a 12.4% increase, respectively). What really separates the Pipercross intake from the OE is the reduction in airflow restriction. At 800CFM the OE airbox and piping saw 1670 mmWg of restriction, while the Pipercross kit only saw 500 mmWg (a 234% difference). With such dramatic changes in airflow and reductions in restriction, the Pipercross kit gives increased throttle response, turbo spool and power increases through the entire rpm range.

*Graphs depict the airflow based in restriction, the lower the line the less restriction.