F150 ecoboost drilled my intercooler

[Raw Dodge]

I get the idea of this hole not being a big deal however the fact remains that the hole is between the air filter and throttlebody ,so there is always a chance of something being ingested thru it.I understand that primarily this area will be under boost pressure but there are times when it is idling and then it probably could easily injest dust,these trucks are commonly used for Deepwater crossings as well I don't think I'd want to put my Eco boost through a muddy stream or a flooded road with this mod.I still think this hole could become a suction straw for road grime..and since the holes on the bottom,it could be a small road Hoover vac....I think I would feel better making a hole 1/8" npt,and thread in a small refrigerator brass water shut off valve..adjust the valve so it just starts to hiss under boost,lock it down .The other option would be a small blow off valve or relief valve at opens around 3 to 5 psi,on the exhaust side of the blowoff put a cap,and drill your 1/16 inch hole in the cap.I love the idea I love the solution Im just not sure I would do it to my truck,and just leave the hole there...

 

[aczlan]

I get the idea of this hole not being a big deal however the fact remains that the hole is between the air filter and throttlebody ,so there is always a chance of something being ingested thru it.I understand that primarily this area will be under boost pressure but there are times when it is idling and then it probably could easily injest dust,these trucks are commonly used for Deepwater crossings as well I don't think I'd want to put my Eco boost through a muddy stream or a flooded road with this mod.I still think this hole could become a suction straw for road grime..and since the holes on the bottom,it could be a small road Hoover vac....I think I would feel better making a hole 1/8" npt,and thread in a small refrigerator brass water shut off valve..adjust the valve so it just starts to hiss under boost,lock it down .The other option would be a small blow off valve or relief valve at opens around 3 to 5 psi,on the exhaust side of the blowoff put a cap,and drill your 1/16 inch hole in the cap.I love the idea I love the solution Im just not sure I would do it to my truck,and just leave the hole there...

On a turbo engine, vacuum only exists after the throttle plate, so the only time the intercooler does not have at least a little pressure is when the engine is shut off.
My worry with adding a valve would be that it would collect water which would then freeze in the winter and break the valve.

Aaron Z

 

[MinnesotaEric]

I get the idea of this hole not being a big deal however the fact remains that the hole is between the air filter and throttlebody ,so there is always a chance of something being ingested thru it.I understand that primarily this area will be under boost pressure but there are times when it is idling and then it probably could easily injest dust,these trucks are commonly used for Deepwater crossings as well I don't think I'd want to put my Eco boost through a muddy stream or a flooded road with this mod.I still think this hole could become a suction straw for road grime..and since the holes on the bottom,it could be a small road Hoover vac....I think I would feel better making a hole 1/8" npt,and thread in a small refrigerator brass water shut off valve..adjust the valve so it just starts to hiss under boost,lock it down .The other option would be a small blow off valve or relief valve at opens around 3 to 5 psi,on the exhaust side of the blowoff put a cap,and drill your 1/16 inch hole in the cap.I love the idea I love the solution Im just not sure I would do it to my truck,and just leave the hole there...

Then screw in a nipple, and put a breather hose on the nipple and mount the other end high.

 

[jejeosborne]

I also though of the option of tapping in a barbed nipple and routing the vent through a hose that feeds some type of collection container. Having the collection containers inlet be metered with a 1/32 inch hole and the other side well vented or possible heated by the engine to evaporate the water only leaving the trace oils in the container.

I am also considering adding a valve that can close off the orifice at will. I am thinking I'm loosing a little bit of boost with this 1/16 hole and wish I had drilled a 1/32 hole. A few full throttle applications lately have netted about 13 psi vs the 16 psi have usually seen at shift points. Next week I will post videos of my boost gage and plug the hole and run back to back test. It might be nice to have a selenoid operated valve that I can cycle once a week or so.

 

[downsizingnow48]

Very interesting thanks for sharing these experiences.

 

[jejeosborne]

My lower boost MAY be due to the cold air in which my test took place. I don't know it the denser air affects how the ECU determines maximum boost. That is why I want to run back to back test minutes apart. Tuesday will be my first opportunity to do this.

 

[s219]

My lower boost MAY be due to the cold air in which my test took place. I don't know it the denser air affects how the ECU determines maximum boost. That is why I want to run back to back test minutes apart. Tuesday will be my first opportunity to do this.

I would almost bet it does -- it's all about the fuel/air mixture, which comes down to the air density. When the air is cooler, you naturally need less compression to get the same density.

 

[WilliamBos]

You going to pitch this idea to Ford? And perhaps every other engine maker too?

 

[jejeosborne]

Well the results are in from my road testing. My maximum boost with the hole was 14.9 PSI and 15.1 PSI with the hole plugged. I am not sure if this is conclusive with such a minor difference. In the video I once mistakenly said smaller hole rather than smaller hill so disregard that mistake. Also I attached my screen shots displaying the values.

Watch "F150 Ecoboost PSI intercooler test" on YouTube
F150 Ecoboost PSI intercooler test: http://youtu.be/FFSQT1ALRak

2015-01-13-12-30-27 by jejeosborne, on Flickr

2015-01-13-12-20-33 by jejeosborne, on Flickr

 

[MinnesotaEric]

People are thinking too much about this. Years ago intercoolers came with weep holes. Here is a video I made with my most sensitive vacuum gauge.

The Result: at idle there is insufficient volume to develop any notable pressure. However, the big idea is if a 1/16" weep hole drilled at the lower left front corner of the intercooler to solve the misfire issue ever draws vacuum, and it does not. As a result, I wouldn't worry about a weep hole at the bottom of the intercooler unless one is crossing a flooded road or doing water crossings. In those conditions, a nipple should be installed, and a breather line popped on that vents at a higher place.