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Old 08-11-2014, 10:24 AM   #1
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Mishimoto Compact Baffled Oil Catch Can Build Thread!

Hey guys,

Our team recently designed a brand new catch can with a ton of neat features. Check out the build process documented below or on our engineering blog!

http://engineering.mishimoto.com/?cat=124

Mishimoto Compact Baffled Oil Catch Can, Part 1: Product Introduction and Initial Design

So we asked ourselves, what makes a catch can appealing to the masses? In a market swamped with extremely low-priced options, a new product could easily get lost in the mix of products already available. Our team began sifting through forums and asking our contacts at local shops to see exactly what they wanted from a catch can. We also reviewed our current line of products, to see if we could develop a new design that would fit within our current offerings.

An efficient catch-can setup is not generally perceived as a product that will impact engine performance or power. This is not true at all! A catch can will make a significant impact on the cleanliness of the intake components, including the charge air cooler (CAC) system, as well as reduce detonation within the combustion chamber. Oil coating the internal components of your intercooler will have a significant impact on heat transfer, reducing the effectiveness of the cooler. By adding an oil catch can you would be improving the reliability and overall performance of your engine. Power gains might not be noticeable, but over time your engine will benefit from running cleaner. The real-world results also show us that a majority of consumers are going to be price-driven, so we would need to consider this as well.

We uncovered a group of consumers who were very concerned with actual product results. Many of them have expensive engine builds and want to be proactive in finding a solution for removing the largest amount of contaminants possible to protect their investment. Another key element was styling, strangely enough. This product is normally quite visible within a vehicle’s engine bay. Unique, engineering-based styling seems to really grab the attention of those peering inside.

So, you may be wondering: How can my car benefit from a catch can? Is the product a gimmick? Will I truly notice the difference? All are great questions. Let’s first take a look at the functions of a catch can.

A catch can? Why do I need one?
The car didn’t come with one from the factory so why do I need one? This is a common question from newbies to the performance automotive world. On your factory PCV/CCV system, fuel and oil vapors pass through lines that make their way into your intake. The engine will then burn off these vapors in the combustion chamber. Although this process eliminates the need for a catch can and is generally considered normal practice in the automotive world, it does have a few downsides.
  • Oil buildup in the intercooler will reduce cooling efficiency.
  • Oil burning in the combustion chamber will lower octane levels and promote detonation.
  • Contaminants will build up in the throttle body and intake manifold.

Why wouldn’t a manufacturer use a catch can, considering the negative impacts above? Well, I would assume the primary reasoning is simplicity and user friendliness. A factory-installed catch can would require emptying on a regular basis. Let’s face it, we humans are lazy. It is tough enough for vehicle owners to remember or even want to change their oil during the correct service intervals. Asking them to empty a catch can would be laughable. Emissions also plays a role in routing CCV vapors back into the intake. The most environmentally friendly way of eliminating these vapors and byproducts is to burn them in the combustion chamber. This keeps the system fully contained. This principle has been a standard for quite some time in both diesel and petrol applications and will likely remain so.

The catch can plays an important role in engine longevity, engine cleanliness, and efficiency of both the combustion mixture and the intercooler system (assuming your vehicle is turbocharged). The catch can mounts inline to the hose that returns to the intake system and works to separate the contaminants prior to their entry into the intake. Air enters into the catch can, where the vapors will be filtered and condensed to promote separation. In theory (and in a proper functioning setup) only clean air will return to the intake, thus protecting your engine from these harmful elements.

Now, why do these gases exist? In simple terms, during engine operation air will flow past the piston rings and into the crankcase area; this is referred to as blow-by. This is unavoidable, as a perfect ring seal is impossible to achieve. Because this air is passing into the crankcase, it will need to be vented to prevent issues. A pressurized crankcase with no relief will result in leaking engine seals, a loss of power (due to its affect on piston movement), oil flow past the rings (resulting in a nice white smoke cloud), and several other major concerns. It is imperative that this air is released in an effective manner. Additionally, modern systems utilize a vacuum source in the CCV system to keep a pull of airflow on the ventilation line.

You may be asking yourself, why don’t I just vent these vapors into the atmosphere? Why return them to my engine at all? Because you are an environmentally conscious individual, that’s why. Returning these oil vapors/liquids to the air is harmful to the environment and terrible for the roadways. Be responsible, keep your vapors to yourself.

Now, don’t assume that these setups are necessary only for turbocharged applications. All engines produce blow-by, some more than others. For example, one of our team members drives a K-series Honda that seems to burn quite a bit of oil, which makes him the target of a reasonable amount of oil jokes during lunch. This also makes it easy for us to find a test vehicle for our new catch can.

Now that we have a general idea of how this component functions and the benefits, let’s jump back into the development of our product.

Project Guidelines
With general information gathered from our customer base and vendors, we began by setting guidelines for our team of engineers to create a catch can that would awe enthusiasts and help extend the life of our customer’s engines. Check out our list below!
  1. Primarily focus on air/oil separation
  2. Smaller footprint than our current baffled catch can
  3. Include a baffle system
  4. Universal mounting system for easy installation
  5. Unique, subtle styling
  6. Develop both a two-port and a three-port catch can

Let’s break these down and expand a bit on each particular project target.

Function Over Form
We love products that look great, but the appearance is negated if they do not function to the fullest. Our primary goal for any product in development is to ensure that it works, and works well. If we can squeeze more performance or functionality out of a component then we will. If we can make it bigger, cooler, more efficient, add new features, or innovate it in any way, our team will do it. For this particular project we will be focusing our performance target on the separation of oil/fuel particles from the CCV/PCV system. We know you are purchasing this product with the anticipation of a clean intake and charge air tract, and we are aiming for that result with our product. Our existing baffled oil catch can utilizes a bronze filter incorporated into the top of the can to separate contaminants. We have found that this setup works extremely well, and our team will use this knowledge to develop our new can. We will be testing this new unit as well, and we will be ensuring that this product performs and protects to the best of our abilities.

Size Matters
Size, a common discussion point surrounding a variety of automotive components. Everyone wants an intercooler the size of a Fiat 126 and a massive turbocharger that frightens small children and instills jealously among other enthusiasts. For a catch can, size is relative to the needs of your particular project. Being that we already offer a larger-sized baffled catch can, we found that some of our consumers would prefer a more compact setup. The need for a smaller can also coincides with the space constraints in the engine bays of modern-day vehicles. Components are getting smaller, lighter, and closer to other engine bay elements. With vehicles in and out of our shop on a regular basis, we have been able to gather some information regarding allotted space for additional components in the WRX, STI, E90, E46, GTO, Powerstroke trucks, Cummins trucks, and more. Our existing oil catch can features the dimensions shown below. Our compact baffled catch can will feature a smaller footprint to better suit the engine bay of modern/sport compact vehicles. Check out the dimensions of our existing baffled oil catch can.


Dimensions of existing Mishimoto Baffled Oil Catch Can

The larger size provides this can with a capacity of 9 fl oz, ideal for use in engine bays with greater space. It also extends the intervals for users to empty the catch can, which is actually quite an easy task with our unit. So in short, we will be developing a catch can with similar features and components to this larger unit, but in a much smaller package.

Bafflin’
A baffle … why would I want a baffle? The inclusion of a baffle in our catch can provides a huge benefit in the performance aspect of the design. A baffle provides for a more effective product that functions much better than the wad of steel wool found in a majority of DIY or inexpensive catch can solutions. Not to put a negative tone or implication on the performance of such a catch can, as these can still be effective, but a properly designed baffling will allow the oil to condense correctly. By adding a baffle we are increasing the internal surface area of the can and providing more locations for the oil vapors to condense. All of this results in greater separation of particles and a cleaner intake for your car. Additionally, the baffle will provide protection from collected oil splashing upward against the filter, which could occur when driving over bumpy terrain or cornering in a high g situation. Our new catch can would have the most effective components we can possibly design, hence the baffle. Although this will translate into a higher price, the improvements are certainly worth the increase in benefits to your vehicle. We will have more information on our baffle design during our second stage of development.

Mount It
Mounting your new oil catch can can be the most challenging part of installation. Our goal here is to provide a can with easy-to-use mounting brackets that will provide as much flexibility as possible. Everyone has a different set of engine bay constraints and locations for mounting, so our hope is to provide one unit that will fit all applications. Additionally, we can probably convince our engineering team to get a bit creative and design these mounts in a unique fashion that screams innovation.

One of our plans with the bracket is a three-slot design. This will allow for a mounting bracket that can swivel nearly 360 degrees to provide the best angle for your inlet/outlet locations. More on this later!

Style
Along with creating a product that performs well, we will want this catch can to look the part. Our team has a way of developing products that are subtle, clean, and unique. We are automotive enthusiasts ourselves, and we understand that all consumers differ on this particular aspect. Our goal is to provide a nice design that satisfies the tastes of as many folks as we can. With our existing product design track record, you can assume this catch can will be quite the looker.

Ports
Our goal here is to develop both a two-port and a three-port catch can. Why would we want to do this? A traditional catch can utilizes one entry port and one exit port, making it a two-port can. CCV air enters the can, is filtered, and returns to the intake tract. We have found that numerous vehicles, such as the Subaru EJ, utilize dual crankcase ventilation lines that necessitate use of a dual-entry can. We will design two catch cans with very similar features, differing in just the inlets. This should provide some flexibility and ease of installation for customers with such CCV systems.

With our guidelines in place, our team began developing 3D renderings using Solidworks software in an effort to produce a basic shape for the project. After several design iterations, we finally came to the rendering you see below.


Initial 3D rendering of Mishimoto Compact Baffled Oil Catch Can

Now that we had a basic outline for the project, we could begin fabricating components and utilizing our 3D printer so we could visualize the can and ensure its features would suit our needs. Check back next time where we begin constructing prototypes!
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Old 08-11-2014, 03:24 PM   #2
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Mishimoto Compact Baffled Oil Catch Can, Part 2: Prototype Development and Testing

Time to fabricate/prototype our awesome catch can design! We would be using our in-house fabrication equipment and our 3D printer to develop a plastic and metal prototype.

Prototype Fabrication
We began by fabricating the base of the can from aluminum. Dan set to work cutting, welding, and polishing the base you see below.


Fabricated base for new oil catch can

Notice that the base of this can does not feature a drain. We did not incorporate one into our initial fabricated component, but we do plan to add a drain port on the base for those who wish to install a valve or drain line to the oil pan. No details were left untouched during development.

Next, we printed a unit and coated the inside for testing. The 3D printed material is somewhat porous. We use an internal coating that properly seals the components and provides a surface with properties similar to our final product.


Fabricated catch can base (right) and 3D-printed base (left)

Next up was the baffle unit. We constructed a few metal prototypes as well as a printed version of our planned baffle design. Notice below that the fabricated units on the left differ slightly. They are primarily for basic mockup, so for this testing we did not need to drill all the holes that would be in the final product.


Fabricated catch can baffles (left, center) and 3D-printed baffle

As mentioned in Part 1 of this blog, this baffle will promote oil vapor condensation, enhance the separation of contaminants, and prevent collected oil from splashing about in the can.

Our next targeted component was the top of the catch can. This would house the ports for air entry/exit, enclose the filter and diverter, and would have provisions for the mounting bracket.


Fabricated catch can components

We chose to 3D-print this top and mounting bracket, and in the meantime we worked toward getting some CNC-machined prototypes constructed. For now, the 3D units would function for our needs and provided a basic glimpse of what this catch can would look like. Don’t worry, we will not be including brass fittings in the final product; these are being used as a representation of the components we will later design. The small white rod attaches the baffle to the lid. The rod is removable, making this catch can very user friendly and serviceable.

Also notice the prototype mounting bracket (bottom left) we printed in 3D. This unit features three slots that pivot around the lid of the catch can. This means you can turn the can nearly 360 degrees, which is a huge advantage when you are situating your inlet/outlet locations. A stationary bracket would limit mounting options, and we found that this pivoting design is very strong and extremely versatile.

Check out the upper portion of this can fully assembled!


Assembled top of prototype catch can


Assembled top of prototype catch can

One component has yet to be discussed, the small silver diverter that is mounted around the filter. Our goal with this component is to increase turbulence within the can to promote greater separation. CFD testing has shown that this simple addition makes a significant impact on air turbulation, which will help our product perform even better.

Now that we had a basic functioning representation of what our catch can would look like, it was time to test the functionality. We prepared a simple bench test that would generate similar conditions to what you would see with a common CCV system. Dan fabricated some mounting devices for the testing components, shown below.


Catch can test-rig assembly

A few quick bends!


Catch can test-rig assembly

Add a few mounting holes and we now have mounts for both the catch can and the pneumatic lubricator. This device (commonly used to oil air tools) will allow us to adjust the oil droplet rate and will atomize the fluid for entry into our catch can. This is an accurate way of introducing a stream of oil vapors/fluids into the can so we can test for separation.


Catch can test-rig assembly

The purpose of this procedure was to test several different filters so we could evaluate their performance and efficiency for separating air and oil. Check out our filter options!


Catch can filter evaluation

With everything prepared, we set up the testing device in two ways. First, we pressurized air before entering the catch can, pushing it through the pneumatic lubricator and then through the catch can. We then looked for the presence of any oil in both the can and the contents of the air passing through the can.


Setup 1 for catch can testing

If you look closely at the image above, you can see the oil building up before entering the catch can. Notice also that the line exiting the can does not have any sign of residue or fluids.

For our second test, we used a venturi tee to create a vacuum-like effect on the catch can and oil. Take a look at the shot below!


Setup 2 for catch can testing

For this setup, air passes through the tee and out to the right. This creates a vacuum effect on the line going to both the catch can and the pneumatic lubricator. This vacuum pulls the air/fluid through the can instead of pushing it, similar to the function of a portion of your CCV system. As with the first setup, oil is present before entry to the can, while the hose exiting the can is completely oil free. Using these two testing setups we were able to evaluate the effectiveness of the filters shown above, eventually settling on the 50 micron bronze filter. Check out a quick video displaying the filter testing.

http://youtu.be/XnurzH2TBN0

Now that we had all of the details sorted out, we CNC-machined a final prototype for our concluding evaluation. Check back next time for a look at this final prototype!
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Last edited by Mishimoto; 08-11-2014 at 03:30 PM.
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Old 08-12-2014, 06:29 PM   #3
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A drain on the bottom and a fluid level indicator on the side -think two external 90* fittings with a clear tube- would do wonders as well.

Thanks for sharing this with the site. I'd think that this, and some of the other things you guys are doing, will help elevate you guys at least slightly out of the "cheap/budget" category of parts. Shows you're trying to grow and create new and better products, rather than just giving the impression of trying to hit in every category with so-so products but a good warranty.
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Old 08-13-2014, 02:26 PM   #4
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Quote:
Originally Posted by Got Insulin? View Post
A drain on the bottom and a fluid level indicator on the side -think two external 90* fittings with a clear tube- would do wonders as well.

Thanks for sharing this with the site. I'd think that this, and some of the other things you guys are doing, will help elevate you guys at least slightly out of the "cheap/budget" category of parts. Shows you're trying to grow and create new and better products, rather than just giving the impression of trying to hit in every category with so-so products but a good warranty.
Thanks Taylor! We find that our development processes are quite interesting and decided to provide some insight into what our team does on a daily basis.

We will be including a drain on the base of the can, this can be utilized with a valve for fluid draining or a fitting to return fluid to the oil pan.

This catch can will not utilize a sight tube to indicate fluid level. The can is very simple to separate which should make fluid checks rather quick.

Thank you very much for the kind words!
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Old 08-13-2014, 02:37 PM   #5
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Part 3 is up! Check it out below.

Mishimoto Compact Baffled Oil Catch Can, Part 3: Final Prototyping

The CNC-machined components keep rolling in! Our last prototype has been constructed and is now ready for our final evaluation before beginning mass production of these units. This prototype is a raw aluminum version; our final version will feature a black anodized finish.

The first completed component is the base/can portion of the product. This is a CNC-machined piece with internal threading on the upper portion, a port on the bottom for a drain or valve, and knurling at the bottom for ease of removal.


Mishimoto catch can final prototype, base


Mishimoto catch can final prototype, base

In the image above, you can see that we did some road testing with this catch can, using one of our employee’s vehicles, to ensure that it was operating as we designed it. Everything checked out, and we caught quite a bit of oil even during short periods of driving!


Mishimoto catch can final prototype, top

The image above shows our final prototype lid/top. This piece features some gorgeous CNC machining. The Mishimoto logo is visible yet subtle on the top. The ports are also labeled in/out for convenience during installation.


Mishimoto catch can final prototype, top

The image of the top above shows three port locations, two threaded and one unthreaded. The smaller threaded port attaches the baffle to the lid via a machine-threaded rod. The larger threaded hole is for our bronze filter, and the smaller unthreaded port is for airflow. The lower portion of the lid is also threaded to mate properly with the base. Check out a few shots below with a fitting installed. As mentioned before, these brass units are being used simply for mockup and not with the final product.


Mishimoto catch can final prototype, top with fittings


Mishimoto catch can final prototype, top with fittings

Next we installed our filter unit, baffle mount, and air diverter. The diverter in the image below is our fabricated component and does not possess the polished finish of our final version. This component will be properly displayed in later images.


Mishimoto catch can final prototype, top with filter and diverter

Our final components include the steel mounting bracket and the aluminum baffle unit. The bracket will provide ample support for mounting the catch can in just about any scenario. Check it out!


Mishimoto catch can baffle (right)


Mishimoto catch can baffle (right) and can-mounting bracket (left)

Now that we had all components, we could fully assemble our prototype. Take a look at what our team created!


Mishimoto catch can final prototype, assembled


Mishimoto catch can final prototype, assembled

The fittings you see attached in this image are representative of what we will include with our final product. These fittings are constructed from a durable nylon material, able to withstand pressures of 150 psi and with an operating temperature range of -50°F to 275°F (-45˚C to 135˚C). We are very confident these fittings will endure years of temperature variation and exposure to fuel and oil. Nylon fittings also provide protection for the aluminum threads in the lid if the fittings were overtightened.

After looking over this component and making minor tweaks and suggestions, we are very pleased with the design. We even mocked up this unit in several vehicles brought to our facility for other product development to make sure it would fit properly. We are also planning to bring a line of direct-fit catch can kits to market in the very near future. This will take the guesswork out of mounting, line routing, and installation for those who prefer products made specifically for their year/make/model vehicles. Check back next time for a look at the finalized catch can!

Thanks
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Old 08-14-2014, 03:16 PM   #6
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Check out the completed product in our last post below! Thanks for following along!

Mishimoto Compact Baffled Oil Catch Can, Part 4: A look at our new catch can!

The project is complete! We are very pleased with the outcome, and we expect a ton of positive feedback on this product. In fact, three or four of our employees have already reserved units for their personal vehicles. Speaking of … I should pick up one for my NB Miata!

The production quality catch can is now prepared for your viewing pleasure. Check it out below, starting with the base of the can.


Mishimoto Compact Baffled Catch Can base


Mishimoto Compact Baffled Catch Can base

Here’s a look at our final catch can top by itself and next to our raw prototype unit. The black anodized finish is durable and looks fantastic.


Mishimoto Compact Baffled Catch Can top


Mishimoto Compact Baffled Catch Can top


Mishimoto Compact Baffled Catch Can top


Mishimoto Compact Baffled Catch Can top (left) and raw prototype top


Mishimoto Compact Baffled Catch Can top disassembled

The neat shot below shows the catch can installed with the base removed, revealing the baffle components. This install features some of the components included in our direct-fit catch can kit for the 2015 WRX, coming soon!


Mishimoto Compact Baffled Catch Can installed without base

Presenting the completed, assembled catch can!


Mishimoto Compact Baffled Catch Can fully assembled


Mishimoto Compact Baffled Catch Can fully assembled


Mishimoto Compact Baffled Catch Can fully assembled


Mishimoto Compact Baffled Catch Can fully assembled

In our final images, you get a peek of the neat packaging we have planned for this catch can. Our creative team put a ton of effort into designing this packaging, and we think it’s pretty slick!


Mishimoto Compact Baffled Catch Can packaged


Mishimoto Compact Baffled Catch Can packaged


Mishimoto Compact Baffled Catch Can packaged

This is what you can expect to receive when you purchase this awesome catch can. Now that we’ve provided the images and insight into what went into the making of this product, let’s look at a quick recap of our goals.

Project Goals

1. Primarily focus on air/oil separation

The catch designed by our engineering team promotes substantial separation of oil from the air passing through your PCV/CCV system. We include a diverter to promote turbulation and a baffle to enhance oil condensation. Additionally, our 50 micron bronze filter works to prevent all contaminants from re-entering into the intake tract.

2. Smaller footprint than our current baffled catch can

This new catch can is much smaller than our previous can and was designed to provide fitment in smaller engine bays. It is 2.5” wide, just under 4” high, with a fluid capacity of 2 fl oz.

3. Include a baffle system

The included baffle system is easily serviced/removed and works to promote oil condensation within the catch can.

4. Universal mounting system for easy installation

This catch can features a sturdy, adjustable, universal mounting bracket that swivels on the top of the can. This design provides a variety of ways for fitting the catch can on your vehicle. The hardware necessary for installation is also included!

5. Unique, subtle styling

Our black anodized catch can features subtle design enhancements while maintaining a stealth-like appearance in your engine bay. This catch can looks as good as it performs.

6. Develop both a two-port and three-port catch can

As you can see from the images above, we will be offering a two-port and three-port catch can. By providing these two options, we are ensuring that our catch can will provide ease of installation for all consumers.



That’s it! The project is complete, and we are just about to release this product to the automotive world. Feel free to follow up with any specific questions regarding our two-port or three-port catch can!

Thanks for reading!

Check out our Engineering Blog for more interesting projects in the development process!
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Old 08-28-2014, 10:06 AM   #7
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Hey guys,

These new catch cans are now available for purchase! Check out the information below. Click any of the links to be redirected to our product page.



Mishimoto Compact Baffled Oil Catch Can

Product Specs
  • Separates oil particles from PCV/CCV air using 50 micron bronze filter
  • 100% billet 6061 aluminum sealed can
  • Defends intercooler, intake system, and essential components from oil blow-by
  • Helps maintain proper octane levels to reduce detonation
  • Features one inlet and one outlet
  • Filter and can are both fully serviceable
  • Safe for pressurized applications
  • Internal air diverter turbulates air longer to improve oil separation
  • Includes plastic barbed 1/2" hose fittings
  • Universal mounting bracket for different configurations
  • Mishimoto Lifetime Warranty

Tech Specs


Images










Catch Can Servicing Video
http://youtu.be/K116LhLVap4

Product Build Log
http://engineering.mishimoto.com/?cat=124

2-Port: Link

3-Port: Link


Feel free to follow up with any questions!

Thanks
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