Mishimoto 6.0L Coolant Filtration Kit Build Thread! - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 26 (permalink) Old 12-05-2014, 03:24 PM Thread Starter
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Mishimoto 6.0L Coolant Filtration Kit Build Thread!

Hey guys,

Our team recently began development of a coolant filtration kit for the 6.0L Powerstroke. We have been documenting the build process to provide a behind-the-scenes look at product development here at Mishimoto. Check out the build on our blog, or posted in the thread below!

Ford 6.0L Powerstroke Coolant Filtration Kit 2003-2006 | Mishimoto Engineering Blog

Mishimoto Ford 6.0L Powerstroke Coolant Filtration Kit, Part 1: Product Introduction and Goals

Project Introduction


Factory 6.0L engine bay

The Ford/International 6.0L was launched in 2003 in an effort to compete with the high power output from the GM 6.6L Duramax, while still meeting new emissions standards. In factory form, the 6.0L Powerstroke is generally reliable and will perform a majority of the tasks demanded by truck owners. Unfortunately, as many have discovered, increasing the power output on the 6.0L produces increased stress on the cooling system, resulting in serious head gasket and other cooling system failures. The head bolts tend to stress with increased power, resulting in damage to the gasket. This knowledge is quite widespread, and the basic fix includes a head resurface, head gasket replacement, and the install of ARP (Automotive Racing Products) head studs. Once replaced, you are free to load the truck with power adding modifications, assuming your tune is properly calibrated.

In addition to the head gasket issues, the 6.0L is also prone to exhaust gas recirculation (EGR) and oil cooler clogging. These clogs can result in decreased efficiency and eventual failure of these components. One of the primary causes for failure is sand from the casting process leaching out over time. As you can imagine, sand circulating through the system can have disastrous effects. Damage can include water pump failure, oil cooler clogging, and EGR damage as well. Truck owners have been dealing with this issue, seeking a solution for constant cooler replacement. Eventually, the aftermarket answered with filtration kits aimed at removing these sediments from the system.

How does Mishimoto fit into the mix? Well, as you may know, our company produces a variety of cooling products specifically for the 6.0L stroker. Our current lineup includes a performance aluminum radiator, silicone coolant hose kit, intercooler, intercooler pipes, a factory-fit boot kit, and both high- and low-temperature thermostats. Our support for the 6.0L community has resulted in a ton of outreach for new product development, one being a coolant filtration system.

Now, the primary issue with this project was the existing products on the market. Several companies already developed these kits, so why even bother? After looking at the offerings on the market, we quickly saw several areas of the kit that could be improved. Thanks to our experience in CNC machining and our knowledge of silicone hose construction, we were confident that we could produce a product with great value for our customers.

First order of business, we needed to develop a few goals for our engineering team to create what we envisioned. Check out the list below.

Project Goals
  • Must be 100% direct fit; make all attempts to reduce the cutting/splicing of stock hoses.
  • Include all necessary components for installation.
  • Utilize valves to reduce coolant loss during filter changes.
  • Use a common off-the-shelf coolant filter for easy customer access.
  • Installation should be simple and utilize common hand tools.

Now, letís go into a bit more detail with these goals.

Direct Fit

As with most Mishimoto products, direct fit is the primary goal. We hope to provide products that install just like a factory-equipped component would. We utilize existing mounting points in an effort to avoid drilling into your truck (whether you mind doing so or not). With this kit in particular, we will be mounting our filter housing in a strategic engine bay location. Additionally, we found that one of the downsides of current kits on the market is the need to cut your factory hoses and splice into them to install the kit. We donít like the idea of cutting these hoses, so we will be attempting to include single-piece hoses with the T-joints and bends built in. This will help eliminate a few potential failure points with crimp or clamp connections.

All-Inclusive

We will be including all necessary components to fully install this kit. This includes the housing, hoses, hardware, and filter. We donít want our customers running all over town to pick up small bits to install our product. Our goal is that you will be able to open our package and install this kit without having to leave your garage or driveway.

Valves

Another important feature for our kit will be the inclusion of valves on the lines. This will allow flow to be cut off to the filter, which will reduce the amount of coolant lost during a filter replacement.

Filter

The actual filter is key to creating the perfect kit for our customers. Not only do we want ideal filtration properties, but we also want this filter to be easy to find. This filter will require replacement on a regular basis, so the goal is to ensure that our customers can head down to the local parts house and pick up a few with no problem.

Easy Installation

Letís face it, no one wants to spend more time under the hood than they have to. We want to get your truck back on the road in the quickest way possible. This kit will be designed to install with common hand tools, and will be simple enough for those who have a basic mechanical aptitude. Additionally, our talented video team will be putting together an in-depth installation guide to help you through the process.

Initial Prototyping

The first component we needed to tackle, the actual housing for the filter, would determine what we would do with the rest of the kit. The fittings and lines we develop would tie into this component. The bracket would then be built in conjunction with the housing. Check out a few of our initial 3D-printed prototypes!


Coolant filtration housing 3D prototype


Coolant filtration housing 3D prototype

Check back with us next time for some additional information about our first prototype, and a look at our CNC-machined housing!

Thanks for reading!
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post #2 of 26 (permalink) Old 12-12-2014, 08:30 PM Thread Starter
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

The next portion of our build is up! Check it out below.

Mishimoto Ford 6.0L Powerstroke Coolant Filtration Kit, Part 2: Initial Design Prototypes

Coolant Filter Housing Prototype

Time for some CNC-machined goodies! Last time we left you with a look at our 3D-printed prototype housing. After reviewing the design and making some minor adjustments, we were able to create a CNC-machined aluminum housing. Check out the results below!


3D prototype housing (right) and CNC-machined housing

And a few close-up shots!


CNC-machined coolant filter housing


CNC-machined coolant filter housing

So letís chat about some of the features you see on this housing. First, this component is constructed from billet aluminum and machined into the proper shape. The inlet and outlet ports are both machined and threaded to accept the valves that we will discuss soon. We then use a threaded filter adapter on the base, which accepts the filter we have selected to use for this project.

The top of this unit features a cylindrical bracket mount that is completely adjustable. Our team is always looking to the future during product design, so we decided to create a housing that could be incorporated into numerous coolant filtration kits, not just for the 6.0L. In fact, we already saw a need for a kit specific to the 6.4L, so development has begun to fulfill that need. We also use subtle silkscreen logos on the top of the housing as well as on the ports to identify which hose connects to each position. This is a really nice piece, and we are extremely pleased with the overall design, as well as the aesthetics. Check out a couple neat shots of this housing from our Solidworks drawing.


Mishimoto coolant filtration kit housing drawing


Mishimoto coolant filtration kit housing drawing

Bracket Fabrication and Prototype

Our next task was to develop a bracket specific to the 6.0L chassis, which would mount our coolant filtration housing in the engine bay. Our goal was to select a location that would provide easy servicing of the filter, while not impeding any other engine bay components. Additionally we would be looking for existing mounting points we could use. After evaluating the engine bay, our team decided upon a location near the radiator support on the passenger side of the vehicle. We then fabricated a bracket that would provide stabilization of the filter and housing. Check out what we came up with!


Fabricated housing bracket

The process by which we create these brackets is quite interesting. Our engineers take all the necessary measurements from the engine bay and our housing, and then they convert them to create a 3D model of the part. This part is then ďflat packed,Ē which means it is placed on a flat plane, while identifying the bends and holes needed to make the part. We can then glue this paper printout to a flat sheet of material and make the necessary bends and cuts. It is a pretty slick process that removes a ton of guesswork out of product fabrication, making our process quick and accurate. Once we confirmed the fitment of our fabricated unit on a test vehicle, a real prototype was worked up.


Fabricated housing bracket (left) and prototype bracket (right)

As you can see above, the bracket design changed slightly through the prototyping process. Initially we were using a three-hole bolt-on design. This was later adjusted to a slotted mounting location that could swivel around a center radius. This design provides greater mounting flexibility and will allow our users to clock the housing in whatever way they prefer. Check out some shots of our prototype bracket.


Prototype coolant filter housing bracket


Prototype coolant filter housing bracket

And a neat look at our drawing for this particular component!


Drawing of coolant filter housing bracket

Check back with us next time for a look at our filter, valve selection, and silicone hoses, as well as this kit fully installed!
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post #3 of 26 (permalink) Old 12-22-2014, 02:29 PM Thread Starter
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

Thanks for following the progress of our build thus far. Check out the final product below!

Mishimoto Ford 6.0L Powerstroke Coolant Filtration Kit, Part 3: Final Components and Project Completion

We are nearing completion of this awesome project! With our bracket and housing finalized, it was time to fill in the gaps for the rest of the necessary components. First up, the filter selection. As mentioned earlier, we were looking for an efficient filter that could easily be purchased at any parts store. We went with the WIX 24070. Of course, any brand that will cross-reference with this filter will also function with our kit.

Filter Selection


Filter

A look at this filter mounted, with the necessary hardware for the bracket.


Filter, filter housing, and mounting hardware

Valves

Our next key components are the valves for the housing and lines. We will use ball-style valves for easy, reliable operation. Check out a couple shots of our plans for this component.


Valve for coolant filtration housing


Coolant filtration housing valve installed

Silicone Lines

Our last component we need to address are the lines needed to install this kit on your 6.0L cooling system. As mentioned in the beginning of this build, we would be working to eliminate the need to splice into your factory lines. An additional goal is to reduce the number of failure points in the system. We did so by creating a system utilizing just two hoses, which are both one-piece units. This eliminates the need for any plastic or brass tees in the system. Check out the hoses we developed!


Silicone hoses


Silicone hoses

Now that we had all of the components completed, we could fully install our coolant filtration system! Check out the final product!


Mishimoto 6.0L Powerstroke Coolant Filtration Kit installed

As you can see, this kit looks fantastic in our test vehicleís engine bay. One of our lines ties into the degas bottle and radiator overflow port. The second line ties into one of the heater hoses. We then set this truck on its way, to start a new life with a cleaner coolant system! Well, with our project complete, it is time to recap our goals to be sure we hit this one out of the park.

Project Goals Recap

1. Must be 100% direct fit; make all attempts to reduce the cutting/splicing of stock hoses.

This goal was easily reached by our team of skilled engineers. This kit bolts into position as if it were equipped on the truck from the factory. The silicone coolant lines we developed for this kit are a complete direct fit and do not require any splicing into your stock lines. The installation of this kit is completely reversible as well, making it easy for you to revert to the factory setup.

2. Include all necessary components for installation.

This kit is all-inclusive and provides all the necessary components for an easy installation. We include the coolant filter housing, bracket, mounting hardware, valves, clamps, filter, and silicone hoses. You will not need to purchase any additional components to install this kit on your truck.

3. Utilize valves to reduce coolant loss during filter changes.

We utilize valves on both the line inlet and outlet ports. This reduces the amount of coolant lost during a filter swap, saving you money and time in the long run.

4. Use a common off-the-shelf coolant filter for easy access.

We designed our kit to function with a common WIX filter or any other brand equivalent. This filter has proven to be very effective at filtration, is relatively inexpensive for our customers to purchase replacements, and is easy to find at local parts stores.

5. Installation should be simple and utilize common hand tools.

This kit is extremely easy to install, and only requires some basic mechanical knowledge/experience. The only challenge for installation will be bleeding the cooling system upon completion, which is a process explained in our installation guide for this kit. If you are unsure about installing this kit, be sure to check out the installation video to get an idea of what lies ahead.

With all our goals met, I think we can put a close on this project. Keep an eye on our site for this kit to hit shelves soon! Thanks for reading our article, and feel free to follow up with any questions or comments!

Thanks.
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post #4 of 26 (permalink) Old 12-23-2014, 03:12 AM
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

Not trying to start a pissing match here, but how will this compare in price to all the other kits out there that are for the most part, the same? Other than the silicone lines, what makes this kit any different or better than brand x that's been available for years now?yes you have your own filter housing, but still use the same wix filter (so filtration is the same as the others), still ties into the coolant system the same as the others, still uses ball valves for filter changes....

So many companies have their own filtration kits, and they are all, for the most part, the same. I'm not knocking Mishimoto at all so don't get that idea. I know yall put out quality products, but if this is like other products you offer, it will be priced substantially higher than every other kit, so basically, the way I see it, a purchase would be based on brand name, considering function is in line with cheaper models.

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post #5 of 26 (permalink) Old 12-23-2014, 05:46 PM Thread Starter
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

Quote:
Originally Posted by 6speedSD View Post
Not trying to start a pissing match here, but how will this compare in price to all the other kits out there that are for the most part, the same? Other than the silicone lines, what makes this kit any different or better than brand x that's been available for years now?yes you have your own filter housing, but still use the same wix filter (so filtration is the same as the others), still ties into the coolant system the same as the others, still uses ball valves for filter changes....

So many companies have their own filtration kits, and they are all, for the most part, the same. I'm not knocking Mishimoto at all so don't get that idea. I know yall put out quality products, but if this is like other products you offer, it will be priced substantially higher than every other kit, so basically, the way I see it, a purchase would be based on brand name, considering function is in line with cheaper models.
This thread is certainly open to comments and suggestions, thanks for posting. Yes, the basic features and functionality are very similar to the other kits currently on the market. We have managed to provide what we see as a superior hose design. We will be offering this kit at a very competitive rate as well. Our goal was to continue expanding our range of cooling products for the 6.0L, and this kit is an awesome addition to our lineup.

We are also planning to perform a ton of additional 6.0L development next year. If you have any product recommendations, or components you could use on your truck, we are open to any feedback or suggestions.

Thanks again!
-John
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post #6 of 26 (permalink) Old 12-23-2014, 06:32 PM
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

I do like the one piece hoses. I hate how my current setup looks with all the hose clamps.,,

Good to see more companies jumping on with the 6.0 and not just writing it off for its flaws. Some of us actually do still love the thing despite all the negativity!

2005 F350 CCLB Dually
Studded, deleted
5" straight piped
155/30's
KC Stage 1.5
Reg return
Beans sump to the stock pump
BPD FICM
Tuned by several...depends on my mood for the day.
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post #7 of 26 (permalink) Old 12-24-2014, 03:33 AM
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

I'm with 6speedSD on this one, the one piece hoses do look good. But please offer them in black color. I hate the red, blue look, I want it all looking stock.

04 F350 DRW 6speed.
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post #8 of 26 (permalink) Old 12-24-2014, 05:04 AM
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

I love the hoses. Do they come in other colors and can you buy them separately?
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post #9 of 26 (permalink) Old 12-29-2014, 03:20 PM Thread Starter
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

Quote:
Originally Posted by 6speedSD View Post
I do like the one piece hoses. I hate how my current setup looks with all the hose clamps.,,

Good to see more companies jumping on with the 6.0 and not just writing it off for its flaws. Some of us actually do still love the thing despite all the negativity!
Thank you for the kind words! The final hoses look great, we are very pleased with how this kit turned out.

Quote:
Originally Posted by ITAcelica View Post
I'm with 6speedSD on this one, the one piece hoses do look good. But please offer them in black color. I hate the red, blue look, I want it all looking stock.
Quote:
Originally Posted by lenzhotrod View Post
I love the hoses. Do they come in other colors and can you buy them separately?
Thanks guys! The hoses will be available in your choice of black, blue, or red.
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post #10 of 26 (permalink) Old 12-29-2014, 08:43 PM
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Re: Mishimoto 6.0L Coolant Filtration Kit Build Thread!

When and will just the hoses be for sale cause?

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