Forge Motorsport Shop

*DOES NOT FIT AUTOMATIC CARS* Designed for the Fiat 500 Abarth T-jet, a front mounting intercooler 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 (standard vehicle + 10 hp, +10 ft/lbs torque) 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. NO CUTTING OF THE VEHICLE IS REQUIRED TO FIT THIS INTERCOOLER               Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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With our extensive development, and the continuing review of our intercooler for the TTRS, we were very eager to use our wealth of knowledge to extract the best possible results with the RS3. Immediately we were able in 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 the Audi had failed to take advantage of. The core measures a massive 530x130x225mm, and is of bar and plate design. The end tanks are designed such that the standard boost hoses can be retained. To ensure that this monster is adequately supported we supply a genuine Audi crash bar, which we modify in house, 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. Rather than release this product immediately after development, we have taken our time with continued testing and tweaking, to ensure that we really have acheived the best possible. We have seen excellent results on both standard cars and those which have been remapped. In fact, on the standard car we had to repeat this several times because we just could not believe what we were achieving, and this presented us with a dilemma... we dont normally quote power figures as they can vary from car to car, dyno to dyno, and they are so variable with weather conditions, fuel used and even how much pressure you have in your tyres! However the gains were so good - on a standard car, with standard software, we saw peak gains of 40bhp in back to back testing. Does this mean that all cars fitted with this will get 40bhp ? Its impossible to say. We're merely including our results here as an indication of how well the core is working.     Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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*For the Veloster N intercooler, please click here* The Forge Motorsport front mount uprated intercooler for the Hyundai i30N. 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 skilfully 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 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.     Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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Product Description 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

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Product Description 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.  

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Highlights: Peak gains of 25bhp Gains of 43nm of torque 113% volume increase Hand fabricated in the UK Kit includes all necessary fittings and instructions included Lifetime warranty This part replaces OEM part number 282702L000 The 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 3.7kg  

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Universal 100 Series Alloy Intercoolers - 60mm Core Forced induction (compression of inlet air) produces heat. Heat can reduce power thus negating some of the benefits of forced induction in the first place. Incorporating an intercooler between the compressor and the plenum chamber greatly reduces the adverse effects of elevated air inlet temperatures. Forge Motorsport’s range of universal intercoolers begin with efficient cores sized to fit many forced induction applications. From there, a wide selection of end tank configurations offer numerous installation solutions. Using the highest quality cores, hand fabricated and welded by highly skilled craftsmen, our intercoolers offer excellent thermal properties, flow characteristics, minimal pressure drop and high volumetric efficiency. We cannot advise if these intercoolers will fit your vehicle. For most applications we need to produce vehicle specific kits, rather than using “Universal” products. However for vehicles that are not covered in our range or where the vehicle is “non-standard” our Universal range can provide the perfect solution. A good starting point is to determine the physical space available to mount an intercooler and use the dimension tables to ascertain what will fit. Then looking at the type variants  (position of the connecting tubes, and diameter, on the intercooler) decide how the hoses need to be routed and connect. Also consider how the intercooler will be secured or mounted. In nearly all cases, when utilising a Universal intercooler, the installer will require a suitable level of technical ability. Finally, if you think that the only answer would be a custom made intercooler, we will be happy to quote you for this, however we will require a dimensional drawing of what you require before we can do so.   100 Series   Core Dimensions - L x W x H mm (in)   Overall Dimensions - L x W x H mm (in) Type 04   500 x 60 x 175 (19.69 x 2.37 x 6.89)   680 x 80 x 200 Type 05   500 x 60 x 175 (19.69 x 2.37 x 6.89)   650 x 80 x 223 Type 06   500 x 60 x 175 (19.69 x 2.37 x 6.89)   650 x 115 x 200 Type 07   500 x 60 x 175 (19.69 x 2.37 x 6.89)   665 x 115 x 200 Type 08   500 x 60 x 175 (19.69 x 2.37 x 6.89)   680 x 80 x 200 Type 09   500 x 60 x 175 (19.69 x 2.37 x 6.89)   680 x 80 x 200 Please select the intercooler type and the tube sizes in the option menus . We can also supply M8 threaded boss mountings or angular brackets as mounting points. Please contact us with your requirements. PLEASE NOTE: PIPE DIAMETER IS THE OUTSIDE DIAMETER OF THE PIPE

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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 Challenge The 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 market The 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 unit Testing and flow analysis has made this product a clear market leader Pressure 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. *Please note - this product does not fit the 2017 JCW cabriolet*   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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This is a replacement for OEM part number 17517617597 As the preferred and official supplier of to www.minichallenge.co.uk Forge Motorsport is proud to present our for the Mini Cooper 1.5 Turbo F56 Chassis. Our core offers a 123% increase in frontal area over stock (BMW Part no 17517617597). As the originators of the stepped core design way back in 2006, Forge Motorsport is best placed within the market to call on our vast expertise in order to deliver a direct fit that would enhance the performance potential of the BMW Group 1.5 Turbo 3 cylinder engine. Our end tanks are die cast in aluminium for improved internal flow characteristics, developed from 3D printed prototypes that we manufactured in-house at our dedicated R&D facility in Gloucester, UK. The bar and plate core design we have used comes after months of testing different core designs and opting for the core with of internal, external airflow and heat transfer characteristics. Please look through the front grill to ascertain which cooler you need. The FMINT8 has 7 tubes the FMINTMF56 has 11 FMINT8 Or FMINTMF56 Official supplier to www.minichallenge.co.uk The Forge F56 JCW gives a respectable 123% increase in frontal area. CNC machined couplers to ensure a precision fit to the OEM Hose couplers. Supplied with all fitting hardware, no additional purchases necessary This is designed as a direct replacement for the OEM 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. Again Forge Motorsport are first to market with a full range of for the Mini (Petrol) F56 Turbo range, 1.5 Turbo Cooper, 2.0 Turbo Cooper s and 2.0Turbo JCW.   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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We took one of the very first UK Mini R56’s produced and immediately set to work to improve the OEM intercooler. We did this with the first ever ground breaking innovative L Shape intercooler core design. Many other companies simply copied this design, but Forge still remain the clear market leader due the exhaustive core testing undertaken in the development stages, we were not content with any air core. The Forge Motorsport development team tested 4 different constructions of air core before choosing the final stuffed fin stepped design intercooler for the 2007 onwards models (R56/R57) BMW Mini Cooper S Turbo. As a reduction in intake air temperature increases the density of the charge mixture within the combustion cylinder, any temperature reductions will equate to more power. This intercooler is constructed using a combined 80/40mm high thermal efficiency core, with a 250% larger surface area and a 125% thicker base core, to achieve the best possible results. In fact, even in relatively low road speeds/air velocities, our intercooler was able to better the OEM unit by 9°C, with greater improvements being achievable during greater speeds during track testing. The replacement intercooler is supplied with all the mountings to allow ease of installation.   Click here to find out about information and care for yourForge Motorsport cooling product.   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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This is a replacement for OEM part number 17517617598 Please note this product does not fit the Mini F57 JCW Official supplier to www.minichallenge.co.uk The Forge F56 intercooler gives a massive 64% increase in frontal area over stock and a correspondingly large increase in volume of 68%. Pressure drop under 1 Psi. CNC machined intercooler couplers to ensure a precision fit to the OEM Hose couplers. Supplied with all fitting hardware, and instructions no additional purchases necessary This 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. High flow cast end tanks to ensure optimum air transition for cooling efficiency Adds more aggressive styling to the front end. Provides a smoother power curve. The Forge intercooler for the F56 utilises a race specification Forge Alsus* designed air core. Dyno proven horsepower and torque gains Forge Motorsport are first to market with a full range of intercoolers for the Mini (Petrol) F56 Turbo range, 1.5 Turbo Cooper, 2.0 Turbo Cooper s and 2.0Turbo JCW. *Please note - this product does not fit the 2017 JCW cabriolet* Please look through the front grill to ascertain which cooler you need. The FMINT8 has 7 tubes the FMINTMF56 has 11 FMINT8 Or FMINTMF56                                                                                                                                                                                                                      Fitment of the core is involved but straightforward using the instructions that we provide, together with a full fitting kit. No cutting is required, this core simply replaces the original.     PLEASE NOTE: THIS WILL NOT FIT THE JCW MODEL.  FOR OUR JCW INTERCOOLER PLEASE VIEW FMINT7   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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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.   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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