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INCREASED COOLING PERFORMANCE FOR 2017+ GEN2 / 2020+ GEN3 RAPTOR AND 2015+ FORD F-150 ECOBOOST

FULL-RACE FORMLINE STAINLESS EXHAUST MANIFOLDS FOR GEN 1 (2011-2016) 3.5L ECOBOOST

MAKE MORE POWER, AVOID COSTLY REPAIRS

Manufactured from cast iron, the OEM log manifolds on the Gen 1 (2011-2016) Ford EcoBoost 3.5L are known to have inherent flaws. When subjected to the 1700+F gas temps seen in these turbo engines under load - the cast iron material has a tendency to warp, crack and or break studs, potentially damaging your cylinder heads. Full-Race's Formline Turbo Manifolds are investment cast using 347 stainless steel at a nominal 3.5 mm (0.138”) wall thickness and are a 100% bolt-on replacement - including new OEM gaskets, studs and nuts.

For years 304 stainless steel has been a go-to material for sturdy, long lasting turbo manifolds and other motorsport exhaust components. But EcoBoost 3.5L owners push their engines hard and demand extreme reliabilty under grueling conditions - failure is not an option. We’ve opted for an upgrade to 347 stainless steel; 347 is commonly found anywhere high temperature and highly corrosive environments exist - from refinery equipment to jet engine parts. This material maintains superior resistance to any type of failure under high temperature operating conditions.


INCREASED FLOW = MORE POWER

When looking at the OEM log manifolds it's immediately apparent the design was controlled by a requirement to be compact, inexpensive and easy to cast.  Log style manifolds have all ports of each bank dump directly into a restrictive common chamber.

Material selection aside, Ford did a good job achieving their goals; but our goals are different. We wanted to develop the ultimate F150 turbo manifold with the only compromise being the extremely tight space needed to fit to remain a bolt-on part. We wanted our manifolds to have some of the same performance characteristics as our hand fabricated turbo manifolds we're known for. Hundreds of engineering hours iterating from 3D scanning to CAD to 3D printing led to our final design that keeps the exhaust pulses from each cylinder from interfering with each other (even at high horspower levels) eventually merging in a collector shared with the rearmost runner.


INCREASED FLOW CAPACITY

The OEM log manifold exhaust chamber is an incredibly small slot-shaped passage. It’s at its narrowest after the front two exhaust ports, right before the third. When this area is converted to an equivalent ‘hydraulic diameter’ it measures only 29 mm (1.14”). Ford expects two cylinders worth of exhaust flow to cram its way through that duct! For reference, that's smaller than the runner we would use for (1) cylinder on a 1.6 L Honda turbo manifold.

Another shortcoming of the OEM log manifold design is the mismatch between the 30mm manifold outlet and the 34.5mm turbocharger turbine inlet. The log manifold has a smaller outlet than the inlet of the turbine housing - meaning exhaust flow is forced to run into a sharp 90° step! This is the least efficient and most restrictive way of joining the flow of two dissimilar sized ducts.

We increased the manifold outlet from 30mm (1.18”) to 34.5mm (1.36”) to match the size of the entry to the turbine housing (also 34.5 mm).  This small change translates into a 32% increase in outlet area.  The next task was to give each cylinder a little bit more breathing room by increasing the runner cross section area. Our new runners start equalling the area of the exhaust ports, and gradually taper down to a minimum diameter of 30 mm (1.18”) each. Compared to the OEM measurement of 29 mm that may not sound like much but remember the Formline manifolds have a min diameter of 30 mm for EACH cylinder!  All this will result in reduced backpressure and increased turbocharger efficiency



FULL-RACE FORMLINE GEN 1 EXHAUST MANIFOLD FEATURES

  • Designed to fit the 2011-2016 Ford F-150 with 3.5L Ecoboost Engines

  • 100% Bolt-On Replacement

  • Investment Cast from 347 Stainless Steel

  • Individual Runner + Merge Collector Design

  • Reduced Back Pressure → Increased Flow

  • Turbine Outlet Port Matched to OEM Turbo (34.5mm)

  • Fits Larger Turbos, unlike other manifolds


SPECIFICATIONS

  • Part Number: FR-TM-FORMLINE-F150-GEN1
  • Material: 347 Stainless Steel
  • Color: Raw Stainless (Ceramic Coating available)
  • Kit Includes: 2x Formline Exhaust Manifolds, 1x hardware kit with studs, nuts and gaskets

APPLICATIONS

  • 2011-2016 Ford F-150 Ecoboost 3.5L

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