Intercoolers

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Forge Audi RS3 8V Intercooler (2015-)

Forge

Following on from our very successful intercooler for the RS3 8P chassis, the Forge intercooler for the RS3 8V chassis builds on our reputation for delivering cores that offer real-world increases in power and temperature drops. Whilst the 8V chassis shares many components with the older 8P, the space available behind the bumper is a different shape and the crash bar has also changed. This required a whole new intercooler and crash bar setup for this latest chassis*The RS3 8V core is a huge 640x250x100 and of bar and plate design. This gives it a huge 55% more surface area than stock, and an even more impressive 94% more volume. The end tanks are made with integrated pipes in order to retain the stock boost hoses, though you can also replace the hoses with our FMKT024 boost hose set if you so wish. Just like on the 8P chassis, we supply a genuine Audi RS3 crash bar which we modify in house in order to accept the new larger core, then finish both the crash bar and core in our standard black crackle finish powder coat for maximum longevity.As shown in the graph below, for both tests we let the car heatsoak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 36°C), then do a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.On the standard car we tested on, it made 362bhp completely stock (so largely in line with what Audi quote) with a peak intake temperature of 58°C. With just this intercooler fitted and no other modifications, the same car made 386bhp with a peak inlet temperature of 23°C, a gain of 24bhp and a drop of 35°C. Gains on mapped cars will likely be even more impressive as the stock intercooler core really starts to struggle on stage 1 mapped cars.The kit contains full instructions for installation, which should take around 3.5 hours, and a complete kit which includes everything needed.If your car is fitted with adaptive cruise control, we can additionally supply you with a billet bracket and fixings to enable the relocation of the ACC radar. Simply select the ACC option in the drop down menu above. No re-coding of the unit should be necessary. The above dyno graph shows a Forge customer making gains of 52HP with this intercooler5 / 5 stars - “In short, this product does what it states!” Working with Litchfield and their Technical Partners (Forge) I have conducted extensive testing to support the development of Litchfield tuning packages for the Audi RS3 8V. Whilst the OEM intercooler is “OK”, very rapidly on repeated road and dyno Wide Open Throttle (WOT) sweeps, the air charge temps quickly rise to levels that impact performance (pulling ignition). To extract the full potential out of the tuning packages and increase repeatability of results and improve overall reliability, I turned to Forge and their upgraded front mount intercooler. Not one for just using a product because of “sales speak”, I extensively tested the Forge offering. The conclusion based on the data logging, mapping and final results was clear. Monitoring charge temps with back to back tests instantly showed us that the cooling efficiency with the Forge product was significantly better. Comparing OEM intercooler charge temps for the coolest first run, against the Forge intercooler on it’s third repeated back to back run (really pushing this comparison with heat soak), the Forge intercooler saw a drop of 18degs peak over the OEM unit (on it’s coolest run with no heat soak). Repeated runs on the OEM intercooler saw the difference widen even more by up to 34degs higher (peak) than the Forge intercooler. Repeated runs between the OEM and Forge intercooler (all completed on the same day) saw the following peak values: OEM - 60degs Forge - 26degs The Forge intercooler also held the lowest charge temperature for longer. This sounds all fine and dandy but what does all this mean in relation to performance? First off Litchfield was able to develop their ECU calibrations without needing to worry about charge temperatures impacting performance. The car spent many hours on the dyno and completed many back to back runs. Over 30 different calibrations were created and tested. Not once did Litchfield need to let the car cool down between runs. The end result was a solid and repeatable 450+bhp achieved with only their ECU calibration, Forge Intercooler and secondary cat removal. Recently (March 2017), the car at this level of modification (Litchfield Stage 2) achieved a stonking 11.5s @ 118+mph quarter mile run at Santa Pod. This is the quickest time that we are aware of in the UK, for an RS3 8V at this level of modification using normal pump fuel, no weight reduction and on stock tyres. The car also achieved the 60mph sprint in 3.2s, the 100mph sprint in 7.9s and 100-200kmh sprint in 8.9s on this same run. I look forward to seeing how the Forge intercooler will complement Stage 3 development. Watch this space!

£1,239.54£1,032.95 (ex. VAT)
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Forge Audi TT 225 Front Mount Intercooler Kit

Forge

Forge were the first company in the world to launch a replacement Front mounted intercooler for the Audi TT225 back in 2014.As the tuners started to modify and increase the performance of the 225 engine, Forge continued to improve the intercooler design to allow for better and more efficient cooling.Three different types of air cores were used in the testing and development of this product. The intercooler was designed on our Solid Works CAD system and flow tested to allow for maximum cooling with minimum pressure loss.With this extra intercooler capacity, remapping the vehicle would bring further performance gains. The intercooler is a direct fit, and no modification or trimming of the bumper is required.Supplied with all fitting hardware, and instructions no additional purchases necessaryThis intercooler is designed as a direct replacement for the OEM intercooler and requires no cutting of bodywork etc.This product is designed, developed and manufactured entirely in Great Britain and is covered by our Worldwide lifetime warranty.Offering significantly reduced inlet temperatures over the OEM and an increase in power of +7 BHP and 8Nm of torque when fitted to a stock vehicle. The Forge Silicon hoses supplied were designed on Solid Works and have been created to include an expensive inner liner of modified silicone known as Flurosilicone.This liner means that the hoses are suitable for use with modern long-life coolants, Organic Acid Technology coolants (O.A.T.) and oil mist.The use of a Flurosilicone liner ensures that Forge silicone hoses are the best, longest lasting, and preferred choice of the discerning car enthusiasts.Will fit ALL Audi TT225 applications including models with headlight cleaning optionTested to 3bar (43.51 psi)Intercooler hoses also available hereThis will fit both RHD and LHD Vehicles Dimensions:550mm x 285mm x 50mmVolume: 7.8 LitresFrontal Area: 1568cm2Note: This is not a direct fit to the Quattro 240 version.

£521.14£434.28 (ex. VAT)
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Forge Front Mounted Intercooler Kit for the Fiat 500/595/695

Forge

Gains of 10 bhpGains of 10 ft/lbs of torque Designed and hand fabricated in the UKFull, comprehensive instructions includedNo cutting of the vehicle is requiredLifetime WarrantyDesigned for the Fiat 500 Abarth T-jet, and also fitting the Fiat 595 and Fiat 695, this front mounting intercooler comes with all associated hoses, pipes, and fittings, that replaces the existing side mounted intercoolers. This unit was developed to be suitable for those running standard turbos and ECU software and also those with larger turbo conversions.Whilst the factory set up using the two intercoolers in parallel is reasonably efficient, the removal of the long lengths of small-bore pipework, quickly lowers the circuit resistance, allowing you to benefit from the true capabilities of the turbocharger. Our development engineers have managed to increase the intercooler surface area by 100% and also increase the volume by 22%. This improvement along with sitting the intercooler at the front of the vehicle to maximise air flow and cooling efficiency, we really do have winner!This kit is available with red, blue, or black silicone hoses. Please select the colour required in the options above. It looks superb on the car and improved my BHP. Worth every penny

£721.84£601.53 (ex. VAT)
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Forge Front Mounting Intercooler for the Peugeot 208 GTi

Forge

The stock intercooler on the 208 GTi is the same compromised side mount intercooler used on the 207 GTi so we know its not up to the job even on a stock car. On a remapped engine with the stock intercooler we were seeing inlet temperatures of 105°C (215°F) the highest we have recorded on any car ever! This has a huge detrimental effect on power and torque.Our intercooler is a full replacement single pass (left to right) core which mounts to the stock crash bar in the car. The pipework supplied with our intercooler joins to the pipes that connect to the stock intercooler so installation is easy. The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone which means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist. The construction of the hoses has been engineered to exceed that of the OEM fitments and will enhance any engine bay both technically and aesthetically - The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader.The only cutting needed is to the ducting on the radiator to allow the pipework to pass through. All the silicon hoses, hard pipes, clips, bolts, nuts and jubilee clips needed to install the intercooler are included, along with full installation instructions. Performance wise, the car we used had a Superchips remap. We tested the stock intercooler and the Forge intercooler back to back on the same day and the increases were dramaticIntake temperature dropped form 105°C to 45°C - a drop of 60°CPower went from 190BHP to 224BHP - an increase of 34BHPTorque went from 222 lb/ft to 244 lb/ft - an increase of 22 lb/ftYou can look at the dyno graph comparison of the intercooler showing the increase in performance, but PLEASE REMEMBER this was specific to the car we had in for testing, and you may not get the same results from a stock or mildly tuned car.All parts necessary for installation are included, together will full instructions.

£854.77£712.31 (ex. VAT)
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Forge Front Mounting Twintercooler for the SEAT Altea 2 Litre FSiT

Forge

On the new 2.0 Litre FSIT engines, there is one sure way to improve on the charge air cooling by using the Forge "Twintercooler". This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band, beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures. We spent many months testing various designs and the Twintercooler design emerged as the clear winner. This is a bolt-on kit that retains the use of the OEM intercooler to produce both horsepower AND torque, but more importantly, a massive reduction in inlet temperatures and increased flow efficiency.A reduction in temperatures of up to 20°C, from 102 to 82, whilst running at 6600 RPM! While the horsepower figures themselves are impressive enough (this may vary from car to car under various circumstances), such a large reduction in inlet temperatures clearly shows this intercoolers ability. Once again we have a Forge product that truly is Engineered for performance.World’s first “Twintercooler “ technology.Unique Twin Core design retaining the OEM intercooler.10-15 BHP increase on a stock car.Over 15 -20 Degree drop in ambient cooling temperaturesIncludes necessary hardware and instructions for installation.Dyno proven horsepower and torque gainsHigh flow cast end tanks ensuring optimum air transition for cooling efficiencyNO CUTTING of the vehicle is required to fit this productThe unique Forge Silicon hoses supplied in the “Twintercooler “ kit were designed on Solid works and have been created to include an expensive inner liner of modified silicone known as Flurosilicone.This liner means that the hoses are suitable for use with modern long-life coolants, Organic Acid Technology coolants (O.A.T.) and oil mist.The use of a Flurosilicone liner ensures that Forge silicone hoses are the best, longest lasting, and preferred choice of the discerning car enthusiasts.The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically.This product has been “designed to last a lifetime “Beware of “Forgeries “

£810.79£675.66 (ex. VAT)
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Forge Honda Civic Type R FK2 Intercooler

Forge

With our extensive development, we were very eager to use our wealth of knowledge to extract the best possible results from the Turbo charged Honda Civic Type R. Immediately we were able to increase the size of the core, allowing much more surface area and cooling efficiency than the stock core. Our intercooler now uses up all the space that Honda had failed to take advantage of.The bar and plate core measures a massive 660x150x120 wide and has up to a huge 100% more volume. The ducting completely surrounds the grill ensuring all of the air coming in the front of the car passes through the intercooler. The end tanks are designed such that the standard boost hoses can be retained, and are of cast aluminium construction. To ensure that this monster is adequately supported, the OEM mounting points are reused, which also eases the installation process. Total fitting time is only around 3 hours if you take your time, and can be fitted on a driveway if necessary.We have seen good power increases, and large temperature drops were achieved compared to the stock core, though it will really come into its own on a remapped engine!Click here to find out about information and care for your Forge Motorsport cooling product. "Highest quality! Finally a great tuning product that does not need modification on a stock car. Easy installation, perfect fit. Performs as expected. Highly recommended.""Fantastic product and extremely well made and designed. Big thankyou to Luke at forge who worked late to fit for me"

£247.20£206.00 (ex. VAT)
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Forge Hyundai Veloster N Facelift Intercooler (Including DCT)

Forge

We are pleased to present the Forge intercooler for the Veloster N facelift including DCT*If you use a Veloster N for fast road or have a high performance tune in a hot climate this product is essential*Utilising our industry leading bar and plate design, alongside Solidworks CAD and flow simulation design (Computational Fluid Dynamics CFD) we developed our high flow cast end tanks. The turbo side endtanks feature an internal divider to ensure the full volume of the stepped core is utilised. The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skilfully integrated into the superior design of this product this ensures fitment to the inner contour of the Veloster N front bumper.The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity.Various core designs where tested in the development of the Veloster N intercooler with us finally deciding to use a high-quality Bar and Plate design as used on our highly successful Audi RS3 and TTRS 8s intercoolers resulting in minimal pressure drop.The results were fantastic with IATS (inlet air temps) being reduced by half and resulting in tremendous gains on tuned vehicles.During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C). We then did a dyno pull from this point. By doing this, it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.After more than six pulls on the dyno we still had super safe IATs and the Forge intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle the results will be even more detrimental and can lead to possible premature engine wear.The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available.

£661.26£551.05 (ex. VAT)
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Forge Hyundai Veloster N Intercooler

Forge

We are pleased to release the Forge intercooler for the Veloster N*If you use a Veloster N for fast road or have a high performance tune in a hot climate this product is essential*Utilising our industry leading bar and plate design, alongside Solidworks CAD and flow simulation design (Computational Fluid Dynamics CFD) we developed our high flow cast end tanks. The turbo side endtanks feature an internal divider to ensure the full volume of the stepped core is utilised. The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skilfully integrated into the superior design of this product this ensures fitment to the inner contour of the Veloster N front bumper.The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity.Various core designs where tested in the development of the Veloster N intercooler with us finally deciding to use a high-quality Bar and Plate design as used on our highly successful Audi RS3 and TTRS 8s intercoolers resulting in minimal pressure drop.The results were fantastic with IATS (inlet air temps) being reduced by half and resulting in tremendous gains on tuned vehicles.During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C). We then did a dyno pull from this point. By doing this, it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.After more than six pulls on the dyno we still had super safe IATs and the Forge intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle the results will be even more detrimental and can lead to possible premature engine wear.This intercooler combined with our intake, and a quality aftermarket cat back exhaust will deliver you unparalleled levels of performance, the final testing results were very notable; not only did the Forge intercooler halve the IATS but significantly increased both power and torque over Hyundai’s claimed figures of 275bhp and 278lb/ft of torque to an impressive 307bhp and 347lb/ft of torque.

£556.20£463.50 (ex. VAT)
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Forge Intercooler for Audi B9 S4, S5, SQ5 and A4

Forge

This front mounting intercooler kit has been designed as an upgrade for the Audi S4 B9 and fits the Audi A4 B9.Offering a huge 128% increase in frontal area and matching increase in internal volume the Forge intercooler is a must have for anyone tuning new twin-entry single turbo 3.0 V6 328bhp engine fitted to the latest in the line of high performance S4 Audi's.Utilising a race specification Forge Alsus* designed Bar & Plate construction and hand fabricated sheetmetal endtanks crafted at our fabrication facility in Gloucester, UK.The core measures 650 x 420 x 50mm.128% increase in frontal area.128% increase in volume.Black powdercoated finish.Supplied with high quality silcone hose, hose clamps, and fixings required for the installation.

£913.43£761.19 (ex. VAT)
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Forge Intercooler for Audi TT RS

Forge

37°C reduction in IATsGains of up to 25BHPOverall surface area increased by 30%Volumetric capacity of 15.7l130% increase in capacity over the OEMOne of the largest intercoolers on the market todayBar and plate core designLifetime Warranty GuaranteeAfter developing an uprated intercooler for the Audi TTRS 8J, our tuning partners approached us to develop a 2nd version that would be specifically designed for those running 500+ BHP. Even for customers with just a stage 1 tune, gains of around 25 BHP can be expected by just swapping out the relatively small and inefficient OEM intercooler (OE Part No. 8J0145804B).The standard intercooler fitted by Audi has a volumetric capacity of 6.8l, which essentially bottle-necks the inlet tract to the throttle body, creating a restriction when the boost is increased. We utilised our CAD design to ensure that the end tanks flow in the best way possible, spreading the compressed air evenly throughout, this in-turn lead to superior performance over the stock item. We tested several core configurations during development, with the best all-rounder being our bar and plate design. The overall surface area of the intercooler has increased by 30% providing more cooling capabilities. We utilised all the available space with a volumetric capacity of 15.7l, resulting in an overall 130% increase in capacity over the OEM, making this intercooler one of the largest on the market today. This intercooler is complimented with our modified OEM crash bar (OE Part No. 8J0807109B), that also doubles as the intercooler support.Why do we test different cores?When developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, and a tube and fin style core. Our tube and fin will be tested with different fin pitches and heights, e.g., 22 fins per inch or 17 fins per inch. We will also look at changing the internal fin pitches/shapes and density within the tube, enabling to fine tune the amount of pressure drop the intercooler produces.Pressure drop is not always a bad thing, as our testing and research has proven on various projects. This is because the pressurized air velocity is being stalled by the pressure drop within the cooler, thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines. As the intercooler reaches its maximum efficiency, the turbo must work a lot harder to force the air through the core. This in-turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is being worked harder.Having no pressure drop can also prove to be inefficient, as the cooler will not lower the charge temperature again, resulting in higher inlet air temperatures.Dyno ResultsTesting was completed using an independent dyno, we used Powerstation in Tewksbury on their MAHA dyno. This was manufactured by the same people who currently supply BMW M Sport and Mercedes Benz for all their engine calibration and dyno testing. During testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 38°C), then did a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge Motorsport intercooler cools much quicker and delivers a greater drop in temperature compared to OEM.The OEM intercooler produced inlet air temperatures on average of 72°C after 3 pulls, while the Forge Motorsport intercooler reduced the inlet air temperature to 35°C, resulting in a 37°C reduction over the stock item, and being far more superior than our first iteration that has since been discontinued.The dyno graph shows the comparison between a highly tuned TTRS running our original revision Forge Motorsport intercooler, and after installing the 500+ BHP version. The results repeatedly showed an increase from the 460BHP previously achieved, to 512BHP, creating gains of +52BHP. We repeated our testing to ensure our results were true and checked all our test vehicles sensor data to ensure there were no negative effects.Finished in our specially formulated textured black finish, and supported by our lifetime guarantee, this is truly an outstanding performance-enhancing product. View this post on Instagram A post shared by Forge Motorsport (@forgemotorsport)

£1,177.54£981.28 (ex. VAT)
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Forge Intercooler for Audi TTRS (8S) 2017 Onwards

Forge

Following on from our very successful intercooler for the RS3 8v chassis, the Forge intercooler for the TTRS (8S) chassis builds on our reputation for delivering cores that offer real-world increases in power and temperature drops. Whilst the 8V chassis shares many components with the TTRS 8S, the space available behind the bumper is a different shape and the crash bar has also changed. This required a whole new intercooler and crash bar setup for this latest chassis.The TTRS core is a huge 640x250x100 and of bar and plate design. This gives it a huge 56% more surface area than stock, and an even more impressive 94% increase in volume. The end tanks are made with integrated pipes in order to retain the stock boost hoses, though you can also replace the hoses with our FMKT024 boost hose set if you so wish. Just like on the 8V chassis, we supply a genuine Audi TTRS crash bar which we modify in house in order to accept the new larger core, then finish both the crash bar and core in our standard black crackle finish powder coat for maximum longevity. As shown in the graph above, for both tests we let the car heatsoak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 36°C), then did a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.On the stage 1 car we tested on (with map and exhaust modifications), it made 470.5 bhp with a peak intake temperature of 76°C. With just this intercooler fitted and no other modifications, the same car made 520.8 bhp with a peak inlet temperature of 34°C, a gain of 50 bhp and a drop of 41°C. Gains on stage 2 mapped cars will likely be even more impressive as the stock intercooler core really starts to struggle on just stage 1 mapped cars.The kit contains everything needed for installation including full fitting instructions, which should take around 3-4 hours.

£1,169.64£974.70 (ex. VAT)
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Forge Intercooler for BMW F20, F21, F22, F23, F30, F31, F36, F87 Chassis

Forge

Forge designed and manufactured specifically for an engineered fit to your BMW Chassis. Utilising a solid works designed high flow hand manufactured end tanks.High density bar & plate construction air core.A simple and easy direct bolt on to the OEM position.Includes all hardware needed to install.Vehicle FitmentsF20, F21 Chassis118i ,120d ,120dX, 125d, 125i, 135i, F22,F23 Chassis218d, 220d, 220i, 225d, 228i, 235i, F30, F31, F34 Chassis316d, 316i, 318d, 318dX, 320d, 320i, 320dX, 325d, 328i, 330d, 335d, 335iF32, F36 Chassis420d, 420dX, 420i, 420iX, 418d, 420d, 420dX, 420,i 420iX, 425d, 428i, 430d, 435d, 435iF87 ChassisM2This uprated intercooler has been designed for the BMW vehicles with the N55 3.0 single turbo engine and N54 twin turbo engine, we have again managed to retain a very easy installation (taking less than 45 minutes with no need to remove the bumper), but also NO cutting of any bodywork. With our testing results indicating a temperature drop of 25°C and of course the increase in power that you would expect from a much larger cooler charge, plus the ability to install this on your driveway at home, we have a truly excellent product.After considerable trials with different intercoolers cores, we have again opted for a core of bar and plate design, and along with an overall increase in dimensions we have been able to drastically improve the cooling ability when compared to the factory intercooler. In the construction, we use CNC machined bayonet couplers which allow an easy plug and play install. The intercooler is supplied with easy to follow instructions.Our before and after Dyno runs clearly show, not only the power increase, but the significant reduction in intake temperature.

£724.03£603.36 (ex. VAT)
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Forge Intercooler for BMW Mini R60 Cooper S

Forge

This uprated intercooler has been designed as an upgrade Mini Countryman Cooper S models. After considerable trials with different intercoolers cores, we found that the most efficient for these models, was an intercooler of bar and plate design, and along with a significant overall increase in dimensions we have been able to improve the cooling ability and reduce the pressure loss across when compared to stock.Our own road and dyno testing showed that our intercooler was twice as efficient as the original intercooler with the inlet temperatures halved.The uprated intercooler is supplied with all parts required for the installation and comprehensive instructions.

£557.75£464.79 (ex. VAT)
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Forge Intercooler for Hyundai i20N

Forge

Highlights:Peak gains of 25bhpGains of 43nm of torque113% volume increaseHand fabricated in the UKKit includes all necessary fittings and instructions includedLifetime warrantyThis part replaces OEM part number 282702L000The Hyundai i20N is an impressive hot hatch with plenty of potential for being fun and fast. However, when looking at the OEM intercooler our development team were able to see that this will be a weak point for those owners looking to push more power or enjoy spirited driving and track days.Our development team started with what we learnt from the successful FMINT15 for the Hyundai MK3 i30N, as the 1.6 litre engine in the i20N shares the same design concept as the 2.0 litre in the i30N. We hand fabricated end tanks as a starting point to create a mock-up intercooler, allowing us to understand design parameters. This was then 3D scanned, allowing our development team to fine tune and produce the biggest core with the smoothest flowing end tank design for the available space.SolidWorks CAD and Computational Fluid Dynamics (CFD) was utilised to develop our high flow cast end tanks. This helped us to incorporate a turbo side internal divider to ensure the full volume of the stepped core is utilised for maximum cooling. With the design completed, we 3D printed the end tanks using our Formlabs Form 3L printer, to then test fit to the vehicle to sign off the new design. To complete the development, we had one-off sand-cast end tanks manufactured allowing us to test the design before manufacture was started on the Forge Motorsport performance intercooler.Our industry leading bar and plate core is an increase of 113% in volumetric capacity and an increase of frontal surface area of over 57% than the OEM intercooler/Heat exchanger. FMINT28 is the largest currently available on the market. The inlet and outlet sizes have both been increased in diameter, the hot side from 50mm to 60mm giving a volumetric increase of over 44% from the OEM intercooler, and the cold side from 50mm to 63mm giving a volumetric increase of over 59% from the OEM intercooler.Testing was completed using Performance Remap in Gloucester with their VTEC 4-wheel drive dynamometer. This was to ensure all our data has been achieved with results as accurately as possible by an independent tuner. As you can see from the dyno results below, peak power was increased from stock by 11bhp and 43nm of torque with the Forge Motorsport performance intercooler installed. The best news is that there are significant gains across the entire rev range, meaning that the car will pick up quicker and pull the whole way through to redline, including up to 25bhp increase over stock at 4500rpm.To give consistent result which reflects real-world driving conditions, the dyno pulls were done with the car up to temperature with the radiator fans tripped on. With the OEM cooler two consecutive runs showed a maximum temperature of 44°C at 6747rpm. With FMINT28 installed we ran four consecutive runs, and the temperature didn’t rise to any more than 32°C at 6717rpm. This 12°C is a massive temperatire decrease of 32%.It’s also worth noting that the dyno cells ambient temperature rose from 24°C to 29°C between the test days so you may experience even better results. With this reduced intake air temperature (IAT), you will prevent the stock ECU from pulling out the engines timing which results in a loss of power. If you use a i20N for fast road or have a high-performance tune in a hot climate, this performance intercooler is essential. This intercooler combined with our intake, and a quality aftermarket cat back exhaust with factory software will deliver you unparalleled levels of performance. The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available. The Forge intercooler weighs 9.65kg compared to the OEM's 3.7kgComplimentary ProductsDump ValveOil CapBrake LinesInduction Kit

£649.99£541.66 (ex. VAT)
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Forge Intercooler for Peugeot 308 GTI Mk2 (2015-2020)

Forge

This intercooler is available to UK customers exclusively from Godspeed - 01656 723060This part replaces OEM part P9813218680 - EP6 EngineForge Motorsport are proud to present a complete plug and play intercooler solution for the Peugeot 308 GTI. With reports of the IATS (inlet air temps) reaching dangerous levels on track days in the summer months resulting in the engines ECU pulling out timing to prevent detonation. This can cause damage to your vehicles engine thus resulting in a loss of power in the highly tuned 1.6 litre turbo charged power plant.The vehicle used to develop the product kindly loaned to us by Godspeed Brakes has been frequently used on track and tested to its limits, without any modifications to the vehicle’s bodywork. The Forge Motorsport development team have managed to increase the volume of air passed through the air-to-air intercooler by the turbo charger to over 74% with a frontal area increase of 8% over the factory OEM supplied intercooler.FMINT30 is finished in our anti-corrosion powder coating which not only helps preserve this intercooler from harsh environments but also aids its thermal properties. Alternatively it is available in our raw alloy motorsport finish and as with all Forge Motorsport fabricated products this intercooler if backed by the legendary Forge Lifetime Warranty.With no extra lag and a proven reduction in IATS this is a must have item for the Peugeot 308 GTI owner who is either using their car for fast road, track days, or competition use. Alternatively, if you intend to modify your 308 GTI with either software (a performance Remap or engine ECU re calibration) the Forge Motorsport intercooler will aid to give the extra cooling and performance needed to ensure the engine stays reliable, safer, and runs cooler in the hot summer months.With data logging, we found at 6646RPM the IATS did not pass 24°C. This was tested on the third pull on the dyno compared with 40°C on the second pull at 6647RPM with the stock cooler in place. Whilst power increased by 7 BHP at the wheel between 4500RPM and 6200RPM, with a 12NM of torque gain at 5200RPM and a consistent gain between 4300RPM and 6000RPM.This Intercooler kit is a complete bolt on package and in turn means it is also fully reversable if required, it is also supplied with a full set of comprehensive instructions.Complimentary ProductsOur uprated Forge dump valve for the Peugeot 308 GTI has been expertly manufactured and designed in the UK, meaning we can provide the industry leading valve for your vehicle. Specifically designed for the Peugeot 308 GTI, this is a fully atmospheric blow off valve, so you can enjoy that fantastic “pshh” sound! This part replaces OEM part number 9808798580A set of 4 ultra-high performance brake lines. These are a direct replacement/upgrade for the OEM brake line set and require no further modifications to fit.These lines are hand-finished with Teflon-lined braided stainless steel bodies and custom-machined stainless fittings, resulting in a brake hose that will perform under the most extreme and harsh conditions, whilst still looking good and performing at the highest level.

£479.99£399.99 (ex. VAT)
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Forge Intercooler for the Audi A4 2.0T Petrol

Forge

This front mounting intercooler kit has been designed as an upgrade for the Audi 2.0 TFSi (B8 models) and A5 2.0 TFSi. After extensive testing, we found that the most efficient core design for these models, was of a tube and fin construction, and along with an increase in surface area, plus an overall dimensional increase, we have been able to improve the cooling ability and reduce the pressure loss across our intercooler, when compared to stock intercooler.With testing conducted both on road and on the dyno, to ensure that this kit really worked, our results showed both a reduction in inlet temperature, an increase in horsepower and torque, but with no detrimental effect on lag or spool up time. The Dyno results gave a respectable +12hp and + 28 ft/lbs on a standard tuned engine, with increased benefits when software tuned. The hoses used are available in red, blue, or black. Please select your colour choice in the options above when ordering.

£882.78£735.65 (ex. VAT)
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Forge Intercooler for the Ford Fiesta 1.0 Ecoboost

Forge

With modern day aftermarket ECU tuning pushing powerful engines harder, in certain conditions the vehicle will run the risk of receiving inadequately cooled air affecting the engines efficiency and ultimately losing power.With this in mind Forge Motorsport are proud to release their Intercooler solution for the Ford Fiesta 1.0 Ecoboost. Following exhaustive testing on the road and dyno working with 3 different manufacturers of air core, we are proud to present the ultimate in front mount intercoolers for the Fiesta.This intercooler is a clear market leader:Twice the internal cooling capacity over the OEM intercooler300% larger cooling surface areaMore than 25 degrees C cooler intake temperatures on a mapped stage 2 car.The largest intercooler on the marketUnlike our competitors this intercooler kit is supplied with our own Forge branded silicone boost hosesAll of the Forge boost hoses have been designed to include an expensive inner liner of modified silicone known as Flurosilicone which means that the hoses are suitable for use in areas that may see oil mist i.e. boost hoses. The use of a Flurosilicone liner ensures that Forge silicone hoses are the best, longest lasting, and preferred choice of the discerning car enthusiast.The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically.No gimmicky 3 year warranty. We stand behind our products and will give you the Forge Market leading Lifetime warrantyClick here to find out about information and care for your Forge Motorsport cooling product.

£399.99£333.33 (ex. VAT)
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Forge Intercooler for the Hyundai i30N Mk3.5 Facelift

Forge

Following the success of our FMINT15 for the Hyundai MK3 i30N it was only obvious we should further development on the face lift MK3.5, with only a few minor design tweaks our plug and play solution is now available for the latest of Hyundai’s revision. With Hyundai redeveloping the turbo charger to run more boost and a larger flow than the previous generation there is even more reason to replace more restrictive OEM intercooler with the larger Forge Motorsport item, based on a stage 2 ECU calibration and fitted with the Forge intake (FMINDK28) and turbo inlet adaptor (FMTIA10) the new intercooler performed as expected,As you can see from the dyno results below, power was increased from 358 bhp with the stock intercooler and intake, to 381.2 BHP and 371.4LB/FT of torque with the Forge Motorsport parts installed.The Forge intercooler helps keep the IATS a safe level and prevent the stock ecu from pulling out the engines timing resulting in a loss of power. If you use a i30N for fast road or have a high performance tune in a hot climate, this product is essential. Utilising our industry leading bar and plate design alongside Solidworks CAD and flow simulation design (Computational Fluid Dynamics - CFD) to develop our high flow cast end tanks, the turbo side endtanks feature an internal divider to ensure the full volume of the stepped core is utilised. The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge Motorsport intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skillfully integrated into the superior design of this product.The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm - up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity.During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C), we then did a dyno pull from this point, in doing this it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.After more than six pulls on the dyno we still had super safe IATs and the Forge Motorsport intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear.This intercooler combined with our intake, and a quality aftermarket cat back exhaust with factory software will deliver you unparalleled levels of performance. The final testing results were very notable - not only did the Forge Motorsport intercooler halve the IATS, it also significantly increased both power and torque over Hyundai’s claimed figures of 275bhp and 278lb.ft of torque, making an extremely impressive 307bhp and 347lb.ft.The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available.

£661.26£551.05 (ex. VAT)
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Forge Intercooler for the Renault Clio RS200 1.6 Turbo

Forge

The latest generation 1.6 turbocharged Renault Clio features a side mounted intercooler from the factory that is both in the wrong location and too small for the standard car, let alone cars that have been ECU tuned. The Renault solution for the Clio Cup cars was to retrofit the entire grid with water spray cooling for the core, but still this was inadequate on the track after a few laps. Given a 15°C day, the typical temperature for the Renault core is over and above 50°C, where our core maintained temperatures between 15 and 20°C cooler.Due to the location of the standard core and the routing of the air conditioning pipes, going any larger is impossible in the stock location without making major changes. Our solution was a front mounted intercooler that utilises the lower open grille in the bumper, ensuring a good supply of cooled air through the core. The kit we supply comes complete with all the pipework, hoses, clamps, nuts, and bolts required for installation. Fantastic high quality product. Installing was relatively easy due to easy-to-follow instructions

£599.99£499.99 (ex. VAT)
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Forge Intercooler for the Renault Megane Mk4 R.S 280/300

Forge

Hand fabricatedLightweight - Tube and Fin coreStepped core design41% capacity increase over OE intercoolerGains of 8bhp (see description for more information)Gains of up to 20NM (see description for more information)FMINT17 is our intercooler upgrade for the Renault Megane Mk4 R.S. We had received reports of this vehicle producing high IAT’s especially in hotter climates when driven hard. Our objective as always was to improve and overcome these issues as well as manufacture a product to the highest standard and quality. This however was not going to be a quick or easy process as with the Megane IV, R.S, Renault had decided to utilize a setup which does not lend itself well to improve its cooling package without a costly overhaul. Renault even went to the extent of using members of it’s F1 team to help with the design of this vehicle so the challenge to improve it cost effectively has been difficult, but with FMINT17, we have achieved this goal.Using our highly skilled CAD team and fabrication department we went to work designing an intercooler which would occupy the original space without the need to modify the vehicle, while at the same time design a product with a greater capacity core for the optimum performance. The end tanks have been a key part of the design of this intercooler, and we have opted for our classic and proven sheet metal construction which is folded in a way to produce a shallow and fast flowing design with negligible back pressure. It is also lightweight as this was another key element in our design brief, to manufacture a high performing intercooler as light as we can; this element also has a significant impact on our choice of intercooler core.Once we had produced an end tank design, we specified several different intercooler core constructions before we started our vigorous dyno testing. Our research and compiled data pointed to the use of a tube and fin core construction, this UK manufactured component really worked well and again was the best option to keep weight to a minimum. The stepped core design is 41% larger in capacity over the OE intercooler and the final product achieved gains of 8bhp with an increase of 12NM of torque between 1900 RPM and 2500 RPM along with 20NM between 5500 RPM and 6000 RPM.This makes the Megane feel and pull stronger at the top of the rev band and when combined with a vehicle equipped with upgraded ECU software like our development vehicle the whole package transforms the 1.8T power plant into the motor this Megane R.S deserves.FMINT17 is finished in our anti-corrosion powder coating which not only helps preserve this intercooler from harsh environments it also aids its thermal properties. As with all Forge Motorsport fabricated products this intercooler has the legendary Forge Lifetime warranty. Why do we test different cores?Here at Forge Motorsport, when developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, a tube and fin style core along with different fin pitches and heights e.g. 22 fins per inch or 17 fins per inch, as well as changing the internal fin pitches/shapes and density within the tube enabling to fine tune the amount of pressure drop the intercooler produces.Pressure drop is not always a bad thing, as our testing and research has proven on various projects. This is because the pressurized air velocity is being stalled by the pressure drop within the cooler thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines as the intercooler reaches its maximum efficiency the turbo has to work a lot harder to force the air through the core. This in turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is over stressed and worked harder.Having no pressure drop can also prove to be inefficient as the cooler will not lower the charge temperature again resulting in higher inlet air temperatures. Dyno ResultsTesting was completed on Litchfield’s Maha dyno, manufactured by the same people who currently supply BMW M sport and Mercedes Benz for all their engine calibration and dyno testing. We also took the opportunity to use Performance Remap Gloucester dyno to compare results and ensure the most accurate data.The stepped core design is 41% larger in capacity over the OE intercooler and the final product achieved gains of 8bhp with an increase of 12NM of torque between 1900 RPM and 2500 RPM along with 20NM between 5500 RPM and 6000 RPM.Complimentary ProductsThis blow off, or dump valve, is for the Renault and Nissan Turbo engines that have the electronically controlled bypass valve (OEM Part no. 144839204R). It is recommended for any vehicle where the boost pressure has been increased by an ECU software upgrade and for unmodified vehicles operating in warmer climates, as a solution to the many failures that have occurred.With the success of the existing range of Forge Motorsport product for the Renault Megane R.S 280/300, we have decided to further expand our tuning parts range for this vehicle. We are excited to offer the FMTIA4 turbo inlet adaptor. Designed and developed by our highly skilled team on the SolidWorks CAD system, the all billet turbo adaptor and high flow silicone inlet pipe is proven to benefit your engines performance.The Renault Megane RS 280/300 intake is the result of widespread design trials through dyno testing and flow analysis. It was developed to achieve three main objectives: Maintain low inlet temperatures in comparison to other aftermarket induction kits; Improved air flow; look aesthetically pleasing and enhances the look of your engine bay

£674.99£562.49 (ex. VAT)
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Forge Intercooler for the Renault Megane RS250/265/275

Forge

With the known deficiency of the RS250/265/275 Radiator in hot climate conditions, we were asked to develop a front mounting intercooler with a minimum air flow restriction to the OEM radiator, but also one that shows a significant improvement in the cooling compared with the original intercooler.Through the use of a high efficiency intercooler core and changing the airflow characteristics with frontal ducting, we have created the perfect solution. Test results show not only a gain of 12 bhp, but also show the + 10 ft/lbs of torque that has been gained across the rev range. This is really felt when driving the car, along with the fact that the power is available for longer as the revs increase. Quoted performance figures are from tests carried out in a standard and stage 1 tuned engines with standard turbo fitted. Results will vary in heavily modified engines with high flow turbo chargers fitted.

£756.70£630.58 (ex. VAT)
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Forge Intercooler for Volkswagen T5 1.9/2.5 and T5.1 2.0 TDI Single turbo

Forge

Uprated front mounting intercooler for the VW T5 bus or van variants. Although significantly larger than the original intercooler, this unit is a direct plug in replacement requiring no additional hoses or pipework. With a larger front cross sectional area, the cooling/power recovery is improved. The unit offers a lower resistance, compared to OEM without adding turbo lag. On our own van we gained 10hp and 20 ft/lbs of torque with just the intercooler, and all who drive the vehicle since the installation have commented on how much better it feels.For those that have used a tuning box, or have updated engine management software, this really is a must.Stock Intercooler: 720x215x30Forge Intercooler: 680x290x40 Fits the following engines: AXB, AXD, AXE, AXC, BRR, BRS, BNZ, BPC, BLU, CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB. This will aslo fit the new 2010 onwards Vw T5.1 2.0TDI single turbo 140bhp, 114bhp, 102bhp, 84bhp models.Fitting GuidesVW T5.2VWT5

£562.82£469.02 (ex. VAT)
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Forge Intercooler for VW T5.1 Twin Turbo

Forge

This intercooler has been specifically designed for the VW T5.1 fitted with the twin turbo diesel. Using a combination of greater core size and thermal efficiency, we have been able to improve the cooling of the intake charge air, which in turn means more power when compared to the original intercooling, and may lead to greater longevity of engine components, as heat related stress is decreased.Our own test vehicle consistantly showed that our intercooler reduced the intake air temperature by a further 10°C when compared to the original intercooler, and had a lower resistance resulting in a pressure drop.This product would normally be recommended for those who have tuned the engine by using performance software or a tuning box type interceptor, but it may also aid fuel economy depending on driving style.*Please note that the oil cooler as displayed in the product images, which will help reduce temperatures further, must be purchased seperately.

£562.82£469.02 (ex. VAT)
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Forge Intercooler Upgrade for Porsche 997 Gen 2

Forge

Following on from our huge success in developing intercoolers for the Porsche 996 and 997 Gen1, we just had to take a look at the 2nd generation Porsche 997.As previously, we started with improving airflow through the intercoolers with the use of enlarged 60mm silicone hoses, and a redesign of the intercooler end tanks. Then with the charge air sorted, we looked at the cooling air that passes over the intercooler. In a similar fashion to the 996, testing showed that the original OEM ducting performed brilliantly. So, satisfied that it was up to the specification needed, we thought we should aim to make a true directly replacement kit, by designing the intercoolers to install perfectly with all the OEM mountings. The new intercoolers are similar in dimension to the OEM units, but are measurably thicker. The real improvement came with the complete re-design of the intercooler core, after testing proved a bar and plate design to be more thermally efficient in this installation.In tests, the Forge unit managed creditable increase of 20hp. This installation allows the engine to produce more power and torque throughout the rev range, and of course with the engine running cooler, engine longevity should also be improved.The use of the original ducting and mountings results in very tidy and efficient installation.

£1,498.66£1,248.88 (ex. VAT)
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Forge Mini Cooper S 1.6 Upgraded Air To Air Intercooler

Forge

At Autosport 2005, we were proud to release our uprated Intercooler for the BMW Mini Cooper S. After a comprehensive development program involving thorough testing in various environments, we are convinced that you will not find a superior Intercooler for this application. Our development program included the use of many types of Intercooler core and end tank designs. At the initial stages we ran two development projects alongside each other, one an air to air Intercooler and the other an air to water Chargecooler system. The air to air development achieved significantly improved temperature reductions in comparison, which convinced us to solely concentrate on this option. At each stage of development, testing was conducted using a vehicle in various states of tune. (With and without, performance software, supercharger reduction pulleys, bonnet scoops and performance air intake systems). With this Intercooler offering up to a 29% reduction over the original equipment, it is a must for those wishing to increase engine power.

£432.96£360.80 (ex. VAT)
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Forge Mini F56 JCW Intercooler

Forge

As the preferred and official supplier of intercoolers to Mini Challenge, we are proud to present our intercooler for the Mini JCW F56 Chassis (2014-on).As the originators of the stepped core design way back in 2006, we were best placed within the market to call on our vast expertise in order to deliver a direct fit intercooler that would enhance the performance potential of the BMW Group 2.0 petrol turbo engine.Our core offers a 31% increase in frontal area over stock (BMW Part no.17517617600) and a correspondingly large increase in volume of 41%.Our end tanks are cast aluminium, made from 3D printed prototypes that we manufactured ourselves in our dedicated R&D facility in Gloucester, UK. The bar and plate design we have used comes after months of testing different core designs and opting for the core with best internal and external airflow.Official supplier to Mini ChallengeThe Forge F56 JCW intercooler gives a respectable 31% increase in frontal area over stock and a correspondingly large increase in volume of 41%The Forge F56 JCW Intercooler leaves the opposition behind yet again being the first to marketThe Forge development team have used Solidworks software to improve the OEM end tank design, making the Forge cast version a much freer flowing and efficient unitTesting and flow analysis has made this product a clear market leaderPressure drop under 1 Psi.This product is designed, developed and manufactured entirely in Great Britain and is covered by our lifetime warranty.Click here to find out about information and care for your Forge Motorsport cooling product.

£774.05£645.04 (ex. VAT)
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Forge Renault Megane 225/230 Front Mounted Intercooler Kit

Forge

Full instructions are included and no additional purchases necessaryThis intercooler is designed as a direct replacement for the OEM intercooler and requires no cutting of bodywork etc.This product is designed, developed and manufactured entirely in Great Britain and is covered by our worldwide lifetime warranty.Offering significantly reduced inlet temperatures of 30°C over the OEM and an increase in power over the stock coolerTested to 3bar (43.51 PSI)Available in silver, or a black thermal powder coated finish.Massive 70mm end tank constructionLeading the way in cooling forthe Renault turbocharged vehicles for the last 25 years; from the Renault 5 GT and now to the impressive Megane, Forge present another industry winner.Combining our decades of experience and CAD flow simulation software, we have created the ultimate intercooler incorporating the latest technology in tube and fin core with 17 FPI (fins per inch) construction and high flow cast end tanks. This equates to a huge reduction in inlet temperatures and up to 30°C difference in cooling efficiency compared with the original intercooler.You will also feel a significant improvement in torque coming in much lower down the rev range. This intercooler is a great upgrade for both the standard or modified Megane.

£400.00£333.33 (ex. VAT)
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Forge Toyota Yaris GR Intercooler

Forge

Gains of 10bhp and 10lbftTemperature drops of up to 20°CReduced turbo lag, increased responseGreater overall surface area for greater heat dissipationUtilising a race specification tube and fin construction air coreHigh flow cast end tanks ensuring optimum air transition for cooling efficiencyDyno proven horsepower and torque gainsA smoother power curveVolumetric increase of more than 100%, without additional lagFrontal area increase of over 40%Includes necessary hardware and instructions for installationLifetime warrantyFMINT25 is a performance intercooler for the Toyota Yaris GR, produced, designed, and tested at our headquarters in Gloucester UK. Throughout the development process we have strived to improve the efficiency and performance of the Yaris GR’s engine. Our project brief was to develop an intercooler utilising all of the available space available in the original position of the OEM intercooler, and to ensure the inlet air temperature is reduced, without any negative effects on the boost pressure or engine and transmission cooling.Using a combination of scanning software and traditional measuring methods, the design was created. This was then fine tuned by our computational fluid dynamics (CFD) team, and the end tanks were initially created by 3D printers. We then alloy cast our first prototypes from our 3D prints using a sand casting technique and started the testing procedure on several types of intercooler cores.The first iteration fitted the vehicle perfectly, however, our technicians and engineers felt the inlet and outlet should be enlarged along with providing the end user with the necessary boost pipes to ensure flow was maximized on the Toyota`s GR 3 cylinder engine.Before getting to work on the dyno, we spec'd three different type of cores; one of these being bar and plate and two being a tube and fin construction - with all three cores having different internal and external fin pitches and configurations. We then welded the test parts ready for testing along with fabricating an internal baffle to the inlet (hot side) of the end tank. This is to ensure, from our CFD research, that the total volume of the core internal is utilised for optimum performance.Compared to the OEM intercooler, the improved Forge product has a surface area increase of over 42% and an internal volume increase of over 100% as well as Gains of more than 10bhp and 10 lbs/ft. These gains can be even higher depending on your vehicles state of tune and complementing performance products like the turbo inlet adaptor and the inlet duct. As the hot and cold side, inlet and outlet, have been increased to 60mm, we have included within the intercooler kit all the necessary silicone hoses and hardware to complete the installation and connect to the OEM parts.The Forge Motorsport intercooler is a perfect performance enhancing product that fits directly to the OEM mounting points, making for an easy install, in a relatively short period of time. No cutting of any components are needed, making the installation reversible if the vehicle needs to be returned to stock at any time in the future. The core and end tanks are finished in our black textured anti corrosion coating that also aids with its thermal properties and keeps the product looking that bit more stealthy or OEM+.The Forge Motorsport lifetime warranty on all hardware products shows the trust we have in the quality of our products while they are being enjoyed on your pride and joy.Why do we test different cores?Here at Forge Motorsport, when developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, a tube and fin style core along with different fin pitches and heights e.g. 22 fins per inch or 17 fins per inch, as well as changing the internal fin pitches/shapes and density within the tube enabling to fine tune the amount of pressure drop the intercooler produces.Pressure drop is not always a bad thing, as our testing and research has proven on various projects. This is because the pressurized air velocity is being stalled by the pressure drop within the cooler thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines as the intercooler reaches its maximum efficiency the turbo has to work a lot harder to force the air through the core. This in turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is over stressed and worked harder.Having no pressure drop can also prove to be inefficient as the cooler will not lower the charge temperature again resulting in higher inlet air temperatures.Dyno Results Testing was completed on Litchfield’s Maha dyno, manufactured by the same people who currently supply BMW M sport and Mercedes Benz for all their engine calibration and dyno testing.The vehicle used for testing had a full turbo back exhaust along with a DT UK Tuning box. Our first run with an ambient air temperature of 19.5°C, gave results of 301.3 BHP and 286.4 lbs/ft of torque. Later after the 3rd pull on the dyno, the inlet air temp quickly increased to nearly 58°C, with the BHP and torque both decreasing to 295bhp and 278 ft/lbs.Our first test Forge intercooler was on our bar and plate design core. The weather on this day was hotter with an ambient dyno cell temperature of 22.1°C. On our third dyno pull on the bar and plate design, the intercooler yields were 304.4 BHP and 295.5 lbs/ft of torque as shown in the graph below. The inlet air temp is highlighted in pink, and shows the intake air temperature reduced to 44°C. So we had achieved a good gain in torque and a reduction in inlet air temps when the testing environment was actually hotter. For our second test we used a very high density external fin pitch core with a tube and fin design. These cores are typically lighter than the bar and plate counterparts. Again the dyno cell ambient air temps here higher than when we tested the OEM intercooler. This time the results showed we had again achieved an impressive reduction in IAT’s with power figures resulting in 304.1 BHP and 297.6 lbs/ft of torque, inlet air temps on the third pull were no higher than 46°C.Our third and final core to test had a slightly smaller thickness than the two previous variants resulting in a slightly smaller volume, and with the hottest test day so far of all the intercoolers in question at 25.4°C within the dyno cell, we were not confident we could improve on the previous results. The results however speak for themselves. On the third pull inlet air temps stayed at a steady 40°C and with the highest BHP gain at 307.3 BHP, and torque peaking at 296.4 lbs/ft We had found our winning formula. At this point though we did not simply stop; we repeated our testing to ensure our results were true and checked all our test vehicles sensor data to ensure there were no negative effects. Complimentary ProductsAfter discussions with many GR Yaris owners about airbox modifications, Forge Motorsport are proud to release the Toyota Yaris GR Inlet Duct. The Forge inlet duct allows you to add an aesthetically pleasing carbon fibre part to your Yaris GR’s engine bay and help keep your inlet temperatures down during spirited driving and whilst on the track or rally stage. The FMTIA8 is the new turbo inlet adaptor for the Toyota Yaris GR. Throughout the development process we have strived to improve the efficiency and performance of the Yaris GR’s engine and for this product we felt we would offer the whole inlet pipe work as one complete package. FMTIA8 consists of a billet machined turbo adaptor, two 5 ply silicone hoses and mandrel bent alloy hard pipe.It is recommended for any vehicle where the boost pressure has been increased by an ECU software upgrade and for unmodified vehicles operating in warmer climates, as a solution to the many failures that have occurred. The Forge motorsport valve solution is available in either atmospheric where a noise is heard when the throttle is lifted or the factory type non noise recirculating valve.

£792.24£660.20 (ex. VAT)