Mishimoto Build Thread: Evolution 7/8/9 Half-Size Radiator
Jan 30, 2014, 12:38 PM
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Mishimoto Build Thread: Evolution 7/8/9 Half-Size Radiator
Hey EvoM,
The team at Mishimoto has ventured into the Evolution world quite frequently, producing unique and effective products. Our new project is a half size radiator for the Evolution 7/8/9 and we but together a short build thread to document the process from start to finish. Check it out and feel free to follow up with questions or comments!
This post and more can be found on our engineering blog if you are interested in following our team and projects!
2001–2007 Mitsubishi Lancer Evolution Half-Size Radiator, Part 1: Project Introduction and Initial Test Fitting
Our initial test fit donor vehicle
It is hard to argue with the masses who rave about the Mitsubishi Lancer Evolution. A turbocharged, AWD, rally-inspired chassis wrapped in a tastefully designed and aggressive body is enough to provoke envy in anyone, enthusiast or not.
During the past few years, we’ve kept a close eye on the Evolution forums and enthusiast groups, and we’ve also kept tabs on the success of our current products, including oil coolers, intercoolers, radiators, and silicone hose kits. In doing so we have become aware of the needs and wants for products that would make the lives of our customers easier. We found an interesting project that needed support – a half-size radiator for enthusiasts who bolt in large-frame, twin-scroll, and front-facing turbocharger setups. This isn’t a modification you will see on a regular basis, but we saw a need for a reliable, efficient, half-size radiator that was priced reasonably and bolted into the Evolution with little or no modification.
So began our research to discover what our customers would want from a product like this. We recognized that this radiator is fairly specialized for drivers who compete in short sprints either in a straight line or through a course, such as autocross or drag racing. Prior to our design phase we established a few reasonable goals that would provide a good base for the start of the project.
We realize that drivers who are modifying their vehicles to this extent would likely have the fabrication ability or a budget large enough to invest in a cooling solution. That being said, we knew that simplifying this component of the build would make the whole process quicker and easier and would allow for more focus on other aspects of the build (tuning, injector selection, turbo sizing, bottom-end components, etc.). Additionally, every dollar saved is another drop of fuel that can be used for flogging about and scaring friends in test drives. Who doesn’t enjoy that?
Designing our radiator to function fully with OEM hoses would eliminate any time spent behind the parts store counter, coat hanger in hand for sizing up potential hoses. This can be quite a hassle, especially when you get home and discover that your selection is just a bit short. A half-size radiator utilizing factory hoses would make finding replacements easy, and upgrading to a Mishimoto silicone hose set (I wonder who offers these?) even easier.
Proper cooling and direct fitment will be our main focus for this project. It’s great to have a massively powerful vehicle, but what good is it if you have to pull to the side of the road after every third gear pull to let it cool down. Overheating is no fun whether you have a stock engine let alone a built engine you blew your holiday bonus on. The use of an iron block and aluminum head doesn’t help with avoiding a blown head gasket and warping.
So let’s move onward to our first round of R&D!
Our first test-fit vehicle was borrowed from a gracious enthusiast, and we set to work removing the factory components. For fitting purposes we mocked up our Honda Civic half-size radiator and began taking measurements. At this point we discovered the modifications necessary for using the Civic style half-rad: the lower mounting points, the radiator hose inlet and outlet, and the upper mounting points would all require extensive modification. We wanted to eliminate hours of fabrication work with a drop-in design. This fabrication work would require a TIG-welder with adequate skills. This is not a skill everyone has on their resume.
Fan shroud clearance
The photo shows the radiator dropped into the support with the mocked-up OEM fan shroud, as well as a Mishimoto silicone upper hose. This radiator was obviously going to be quite small in width, so we would need to compensate with an increase in depth. The design would include a large core, unique end tanks, proper mounting points for the fan shroud (for OEM compatibility), and accurate inlet/outlet locations for use with factory hoses.
Check out a couple of other images showing the close proximity to the turbo. This particular vehicle was not using a front-facing setup, but our research provided information on where to place the radiator to avoid the manifold runners and turbo. The manifold and turbocharger are rather close to the radiator, so we will need to deal with the additional heat.
Fan shroud clearance to waste gate actuator
Increased engine bay space
Fan clearance would not be an issue with this particular design, especially if a slim fan is used. For convenience this radiator includes OEM fan shroud mounting points. The factory fan puts out a fair amount of CFM but is rather bulky. Upgrading to a slim fan is simple and would allow attachment to either a custom shroud or directly to the core.
Overflow hose and additional engine bay space
Look at all that free space begging for some upgrades!
Radiator mock-up
All the measurements, images, and information collected allowed us to generate a prototype or two for testing. Enter Dan, the lead engineer for this project, who set to work on modeling our potential design. The prototype that emerged promised perfect fitment and exceptional performance. Solidworks renderings looked fantastic, and we were excited to get this project moving.
Check back next time as we solidify our design and perform additional test fitting!
Thanks
The team at Mishimoto has ventured into the Evolution world quite frequently, producing unique and effective products. Our new project is a half size radiator for the Evolution 7/8/9 and we but together a short build thread to document the process from start to finish. Check it out and feel free to follow up with questions or comments!
This post and more can be found on our engineering blog if you are interested in following our team and projects!
2001–2007 Mitsubishi Lancer Evolution Half-Size Radiator, Part 1: Project Introduction and Initial Test Fitting
Our initial test fit donor vehicle
It is hard to argue with the masses who rave about the Mitsubishi Lancer Evolution. A turbocharged, AWD, rally-inspired chassis wrapped in a tastefully designed and aggressive body is enough to provoke envy in anyone, enthusiast or not.
During the past few years, we’ve kept a close eye on the Evolution forums and enthusiast groups, and we’ve also kept tabs on the success of our current products, including oil coolers, intercoolers, radiators, and silicone hose kits. In doing so we have become aware of the needs and wants for products that would make the lives of our customers easier. We found an interesting project that needed support – a half-size radiator for enthusiasts who bolt in large-frame, twin-scroll, and front-facing turbocharger setups. This isn’t a modification you will see on a regular basis, but we saw a need for a reliable, efficient, half-size radiator that was priced reasonably and bolted into the Evolution with little or no modification.
So began our research to discover what our customers would want from a product like this. We recognized that this radiator is fairly specialized for drivers who compete in short sprints either in a straight line or through a course, such as autocross or drag racing. Prior to our design phase we established a few reasonable goals that would provide a good base for the start of the project.
- Design a direct-fit radiator for the Evo 7/8/9 chassis with no cutting or trimming required.
- Allow for full function with OEM hoses and factory fan shroud.
- Provide sufficient cooling and space for large/front-facing turbocharger setups.
- Offer at a reasonable price point for customers.
We realize that drivers who are modifying their vehicles to this extent would likely have the fabrication ability or a budget large enough to invest in a cooling solution. That being said, we knew that simplifying this component of the build would make the whole process quicker and easier and would allow for more focus on other aspects of the build (tuning, injector selection, turbo sizing, bottom-end components, etc.). Additionally, every dollar saved is another drop of fuel that can be used for flogging about and scaring friends in test drives. Who doesn’t enjoy that?
Designing our radiator to function fully with OEM hoses would eliminate any time spent behind the parts store counter, coat hanger in hand for sizing up potential hoses. This can be quite a hassle, especially when you get home and discover that your selection is just a bit short. A half-size radiator utilizing factory hoses would make finding replacements easy, and upgrading to a Mishimoto silicone hose set (I wonder who offers these?) even easier.
Proper cooling and direct fitment will be our main focus for this project. It’s great to have a massively powerful vehicle, but what good is it if you have to pull to the side of the road after every third gear pull to let it cool down. Overheating is no fun whether you have a stock engine let alone a built engine you blew your holiday bonus on. The use of an iron block and aluminum head doesn’t help with avoiding a blown head gasket and warping.
So let’s move onward to our first round of R&D!
Our first test-fit vehicle was borrowed from a gracious enthusiast, and we set to work removing the factory components. For fitting purposes we mocked up our Honda Civic half-size radiator and began taking measurements. At this point we discovered the modifications necessary for using the Civic style half-rad: the lower mounting points, the radiator hose inlet and outlet, and the upper mounting points would all require extensive modification. We wanted to eliminate hours of fabrication work with a drop-in design. This fabrication work would require a TIG-welder with adequate skills. This is not a skill everyone has on their resume.
Fan shroud clearance
The photo shows the radiator dropped into the support with the mocked-up OEM fan shroud, as well as a Mishimoto silicone upper hose. This radiator was obviously going to be quite small in width, so we would need to compensate with an increase in depth. The design would include a large core, unique end tanks, proper mounting points for the fan shroud (for OEM compatibility), and accurate inlet/outlet locations for use with factory hoses.
Check out a couple of other images showing the close proximity to the turbo. This particular vehicle was not using a front-facing setup, but our research provided information on where to place the radiator to avoid the manifold runners and turbo. The manifold and turbocharger are rather close to the radiator, so we will need to deal with the additional heat.
Fan shroud clearance to waste gate actuator
Increased engine bay space
Fan clearance would not be an issue with this particular design, especially if a slim fan is used. For convenience this radiator includes OEM fan shroud mounting points. The factory fan puts out a fair amount of CFM but is rather bulky. Upgrading to a slim fan is simple and would allow attachment to either a custom shroud or directly to the core.
Overflow hose and additional engine bay space
Look at all that free space begging for some upgrades!
Radiator mock-up
All the measurements, images, and information collected allowed us to generate a prototype or two for testing. Enter Dan, the lead engineer for this project, who set to work on modeling our potential design. The prototype that emerged promised perfect fitment and exceptional performance. Solidworks renderings looked fantastic, and we were excited to get this project moving.
Check back next time as we solidify our design and perform additional test fitting!
Thanks
Feb 12, 2014, 09:00 AM
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Feb 12, 2014, 09:09 AM
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2001–2007 Mitsubishi Lancer Evolution Half-Size Radiator, Part 2: Final Testing and Completion
With our design essentially solidified, and our prototypes ready to be put into action, it was time to perform another test fit and gather data. Lucky for us, one of our new engineers (Steve) happens to daily drive an Evo 9, and we talked him into allowing us to use his car for development. Steve’s Evo is making around 350 hp to the wheels with a few modifications and quite a helping of boost. This should be a great vehicle for our second round of testing.
Test fit vehicle #2
Test fit vehicle #2
Into the shop and onto the lift it went. The radiator was installed without any issues. We were able to bolt the factory fan shroud to the radiator and also fit the factory hoses. Score!
Prototype design installed
The end tanks fit perfectly with the radiator support, and our fabricated upper bracket provided additional support for the radiator.
Prototype design clearance to radiator support
After reviewing the fitment and our notes, we established a plan for our final design. The engineers decided to add an internal baffle to the upper radiator end-tank. Because of the placement of the inlet and outlet, the coolant tends to take the shortest route through the radiator. This results in a lower cooling efficiency because the heat transfer time is much shorter. An internal baffle would force fluid to reach the entire core, thus promoting greater exchange of heat and improved reduction in temperatures from inlet to outlet.
We wanted to move the upper hose, but we were still concerned about using the factory hose. By rotating the hose 180° we were able to mate it properly to the new inlet location on the end tank. With the inlet and outlet now located on opposite sides of the radiator, the fluid dispersion would be even greater, further enhancing the cooling efficiency of this radiator.
Solidworks model with internal baffle
Prototype with Mishimoto silicone hose kit
Our finished product is quite impressive and should be right at home in high-horsepower builds. Each feature fits perfectly, from the lower mounting points to the fan shroud mounts. We reached all our goals, and we are very confident that this radiator will provide ideal cooling for drag strip and autocross vehicles. This summer we plan to obtain hot weather testing data as additional supportive information.
Let’s go over the checklist once again in detail!
Goal – Design a direct-fit radiator for the Evo 7/8/9 chassis with no cutting or trimming required.
Result – This radiator fits without any cutting or trimming. We included an additional upper radiator stay for greater support.
Goal – Allow for full function with OEM hoses and factory fan shroud.
Result – Thanks to precise inlet/outlet locations and fan shroud mounting points, this radiator works perfectly with factory hoses and fan shroud. Optionally a slim fan can be used for even greater engine bay clearance.
Goal – Provide sufficient cooling and space for large/front-facing turbocharger setups.
Result – This radiator frees up the entire passenger portion of the radiator support, providing space for large/front-facing turbochargers. The radiator is ideal for use in short spring racing such as drag events and autocross.
Goal – Offer at a reasonable price point for customers.
Result – Pricing for this product will be within the budget of any build!
Looks like we hit everything we were intending to achieve. It is always nice to see a project like this go smoothly. Be sure to check back this summer for updated warm weather testing data for this radiator.
Feel free to follow up with any questions or comments. I would be happy to answer them!
Also, swing by our new engineering blog for updates on this project and many others!
Thanks
With our design essentially solidified, and our prototypes ready to be put into action, it was time to perform another test fit and gather data. Lucky for us, one of our new engineers (Steve) happens to daily drive an Evo 9, and we talked him into allowing us to use his car for development. Steve’s Evo is making around 350 hp to the wheels with a few modifications and quite a helping of boost. This should be a great vehicle for our second round of testing.
Test fit vehicle #2
Test fit vehicle #2
Into the shop and onto the lift it went. The radiator was installed without any issues. We were able to bolt the factory fan shroud to the radiator and also fit the factory hoses. Score!
Prototype design installed
The end tanks fit perfectly with the radiator support, and our fabricated upper bracket provided additional support for the radiator.
Prototype design clearance to radiator support
After reviewing the fitment and our notes, we established a plan for our final design. The engineers decided to add an internal baffle to the upper radiator end-tank. Because of the placement of the inlet and outlet, the coolant tends to take the shortest route through the radiator. This results in a lower cooling efficiency because the heat transfer time is much shorter. An internal baffle would force fluid to reach the entire core, thus promoting greater exchange of heat and improved reduction in temperatures from inlet to outlet.
We wanted to move the upper hose, but we were still concerned about using the factory hose. By rotating the hose 180° we were able to mate it properly to the new inlet location on the end tank. With the inlet and outlet now located on opposite sides of the radiator, the fluid dispersion would be even greater, further enhancing the cooling efficiency of this radiator.
Solidworks model with internal baffle
Prototype with Mishimoto silicone hose kit
Our finished product is quite impressive and should be right at home in high-horsepower builds. Each feature fits perfectly, from the lower mounting points to the fan shroud mounts. We reached all our goals, and we are very confident that this radiator will provide ideal cooling for drag strip and autocross vehicles. This summer we plan to obtain hot weather testing data as additional supportive information.
Let’s go over the checklist once again in detail!
Goal – Design a direct-fit radiator for the Evo 7/8/9 chassis with no cutting or trimming required.
Result – This radiator fits without any cutting or trimming. We included an additional upper radiator stay for greater support.
Goal – Allow for full function with OEM hoses and factory fan shroud.
Result – Thanks to precise inlet/outlet locations and fan shroud mounting points, this radiator works perfectly with factory hoses and fan shroud. Optionally a slim fan can be used for even greater engine bay clearance.
Goal – Provide sufficient cooling and space for large/front-facing turbocharger setups.
Result – This radiator frees up the entire passenger portion of the radiator support, providing space for large/front-facing turbochargers. The radiator is ideal for use in short spring racing such as drag events and autocross.
Goal – Offer at a reasonable price point for customers.
Result – Pricing for this product will be within the budget of any build!
Looks like we hit everything we were intending to achieve. It is always nice to see a project like this go smoothly. Be sure to check back this summer for updated warm weather testing data for this radiator.
Feel free to follow up with any questions or comments. I would be happy to answer them!
Also, swing by our new engineering blog for updates on this project and many others!
Thanks
Feb 14, 2014, 06:58 AM
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Feb 14, 2014, 02:24 PM
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Feb 17, 2014, 06:21 AM
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Great! Yes the OEM fan mounting points are really neat. This way if your setup fits with the stock fan and shroud you can use it. If your manifold/turbo setup does not agree with the thickness of the OEM shroud you can easily throw a slim fan on!
Thanks
Thanks
Feb 18, 2014, 11:51 AM
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Feb 26, 2014, 08:09 AM
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Hey Guys,
This radiator has officially been released! Check out the specs below and feel free to follow up with any questions or comments!
Product Information
- Direct fit for the 2001–2007 Mitsubishi Lancer Evolution
- Half-size design provides clearance for large twin-scroll and forward-facing turbocharger setups
- All-aluminum construction with TIG-welded end tanks
- 2.05” thick brazed aluminum core provides optimal cooling and superior durability
- Internal baffle provides exceptional fluid dispersion throughout the core and optimal cooling efficiency
- Applicable for use with stock or Mishimoto silicone radiator hoses
- Includes mounting points for stock fan shroud
- Includes magnetic drain plug with dowty seal, 1.3 bar high-pressure radiator cap, and upper radiator aluminum stay
- Mishimoto Lifetime Warranty
Tech Specs
Check out some images of the finished product below!
Thanks!
Mar 14, 2014, 02:07 AM
#14
One that would be nice to see, as with the WRX/STI platforms, have a slim-fan kit that is plug and play. When is the Evo community going to see this? (Specifically the 7/8/9s)
Mar 14, 2014, 07:20 AM
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Thanks