Forge Motorsport Shop

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.   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 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. Of course if you are experiencing extreme temperatures or are after the ultimate solution to hot climate running, we recommend using our uprated radiator FMRADRS250 in combination with this intercooler.   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.     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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Leading the way in cooling, the 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. Full instructions are included and 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. Offering significantly reduced inlet temperatures of 30°C over the OEM and an increase in power over the stock cooler Tested to 3bar (43.51 PSI) Available in silver, or a black thermal powder coated finish. Massive 70mm end tank construction   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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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. Please Note: If you require Red hoses please call us on 0145238099 - this will be a special order and it will be a 12 week lead time from the date of order. If you are unsure if this product is suitable for your application, please contact us.  Click here to find out about information and care for your Forge 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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In addition to the Forge Motorsport PolarCooler range, here we have the top mount replacement chargecooler and expansion tank for the BMW MSport S55 Engine. The Chargecooler features an all aluminium construction which overcomes all the issues relating to plastic end tank splitting, failure at high boost and leaks between the core and end tanks with end tank seal failure. The end tanks are fabricated using high precision laser cut sheet metal panels which are TIG welded by hand for maximum strength and durability. Designed and manufactured at Forge Motorsport HQ in Gloucestershire, England, we utilised our Solidworks CAD design system to assist in the creation, modification, CFD (Computational Fluid Dynamics) analysis and optimization of this innovative charge cooler. Three different core constructions were evaluated during the development process. The final design of a bar and plate core far outperformed the other two alternatives. In doing this, the Forge Motorsport development engineers have made a quadruple pass design, allowing the water to flow through four passes of the cooler which improves the cooling efficiency beyond any other products currently on the market. Unique to the market, the Forge BMW M3/M4 S55 Chargecooler system (that also fits the M2 Competition F22 2018-) uses an expansion tank rather than a header tank like the OEM system. There is a filler cap located at the highest point on the Chargecooler allowing you to be sure that the charge is 100% full of coolant with no air pockets. This maximises the efficiency of the heat rejection of the coolant within the Chargecooler water jacket. Offering over 71% increase in volume and over 42% increase of frontal area. In hot climate testing, constant dyno runs showed significantly lower inlet temperatures compared with the stock system and an increase in power of up to 20BHP. As part of Forge Motorsport’s strict quality control process, each chargecooler unit is carefully inspected and pressure tested to 4BAR before despatch. Located on the outlet tank of the chargecooler there is also a 1/8 NPT port ready for water/methanol injection if required. The existing OEM Chargecooler rubber mounts are used for this expansion tank and Chargecooler, isolating the system from the harsh vibrations of the engine. No trimming or cutting of the vehicle is required and all parts can be returned to standard if necessary. In the box 1x Chargecooler unit1x Expansion tank with sight glass1x Expansion tank cap1x Small radiator cap1x Billet radiator cap cover1x Billet blanking cap1x 1/8 NPT Grub screw7x M6x12mm  Allen cap bolts7x 6mm washers1x M8x20mm Allen cap bolt1x 8mm washer1x M8 Nyloc nut3x 8-16mm Hose clamps1 x 8mm ID Vacuum hose x 170mm1x 8mm ID Vacuum hose x 750mm  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 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 degrees centigrade, 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. Vehicle Fitments F20, F21 Chassis 114d, 114i, 116d, 116i, 118i, 118d, 118dX,118i ,120d ,120dX, 125d, 125i, 135i,  F22,F23 Chassis 218d, 220d, 220i, 225d, 228i, 235i,  F30, F31, F34 Chassis 316d, 316i, 318d, 318dX, 320d, 320i, 320dX, 325d, 328i, 330d, 335d, 335i F32, F36 Chassis 420d, 420dX, 420i, 420iX, 418d, 420d, 420dX, 420,i 420iX, 425d, 428i, 430d, 435d, 435i 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 (see images above) clearly show, not only the power increase, but the significant reduction in intake temperature. 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.   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 for the BMW 135 and 335 equipped with the N54 twin turbo and N55 single turbo engine, and BMW 1M equipped with the N54 (twin turbo) 6 cylinder engine. Our criteria was to achive maximum efficiency whilst retaining a simple fitment. With our testing results indicating increased cooling of up to 30 degrees centigrade and the ability to install this on your driveway at home in under one hour, we have just what we wanted. After considerable trials with different intercoolers cores, we found that the most efficient for these models, was a core of bar and plate design, and along with an overall increase in dimensions, we have been able to improve the cooling ability and reduce the pressure loss when compared to a 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 and all the parts required.   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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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 short period of time. Our technicians at Forge have increased the core to its maximum possible size within the parameters of the available space. The core used for this application is our industry leading bar and plate design with curved end tanks to aid better air flow and keeping pressure drop to less than 1 PSI.  This design was created using Solidworks CAD and by using flow simulations along with hours of analysing data, we have created a product that is far superior than the OE intercooler. The core and end tanks are finished in either raw silver aluminium or with a black textured anti corrosion coating, which not only looks superb, but also gives this product added longevity in the harshest of environments. Our 10-row bar and plate core has over 75% more volume and has increased the front surface area by more than 25% over the OE cooler ensuring the Forge intercooler is the largest currently available on the market.  The new Forge intercooler is suitable for fitting with Suzuki’s active cruise control (ACC) and brake assist module without any modification. The end results of our testing: After more than six pulls on the dyno we still had super safe IAT’s (inlet air temps), and the Forge Motorsport intercooler gave results of 20°C, compared to the OE intercoolers 32°C intake temperatures after only one pull.     These tests took place in relatively cold conditions with an ambient dyno cell temperature of 14°C, proving how inefficient the stock intercooler is. In warmer climates, the OE intercooler along with higher inlet air temperatures will have a detrimental impact on the Suzuki’s engine, resulting in the factory’s ECU to pull out timing to prevent detonation; resulting in power loss. On a remapped vehicle, this will be even further highlighted.  Results over the stock intercooler gave some impressive gains, with nearly 9BHP just from a direct intercooler swap. You will also see from the graph below that torque was improved throughout the rev range, with peak figures being almost 10Nm.      Combined with our Forge stage one tune and high flow cold air induction kit we made an impressive 178bhp along with huge torque gains resulting in 275lbft of torque. Dimensions OE Intercooler 690L x 120H x 50W mmFrontal area 828cm²Volume 4.1 Litres Dimensions Forge Intercooler 690L x 150H 70W mmFrontal area 1035cm²Volume 7.2 Litres  The Forge intercooler is supplied with detailed installation instructions which should take in the region of 1.5 hours to install.   "Installed this bad boy last friday and the build quality is amazing, zero issues with fitment and the instructions are very good"   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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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. Although the above dyno conducted by independent tuners MB Garage Services & Motorsport on an RS3, similar gains can be expected on the TTRS The kit contains everything needed for installation including full fitting instructions, which should take around 3-4 hours.    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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Following on from our success in developing an uprated intercooler in 2011 for the Audi TTRS, our tuning partners approached us to develop a 2nd version that would be specifically designed for those running 500+ bhp. With a no holes barred approach our engineers have created yet another success. All the available space is now utilised with our modified crash bumper that also doubles as the intercooler support. The Dynograph shows the comparison between a tuned TTRS running our original intercooler and after installing the 500+ bhp version. The results repeatedly showed an increase from the 460bhp previously acheived to 512bhp, indicating a gain of +52bhp.   Whilst we have retained the utilisation of the original hoses we do recommend the use of silicone hose replacements (product code FMKTTTRS) at this level of tuning. Please note: This intercooler is integrated into a replacement crash bumper and as such, is supplied as a combined item. We only supply this product in a black finish.     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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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 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. 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 option Tested to 3bar (43.51 psi) Intercooler hoses also available here Dimensions:550mm x 285mm x 50mmVolume: 7.8 LitresFrontal Area: 1568cm2 Note: This is not a direct fit to the Quattro 240 version.   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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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. 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 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 deg 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. Click here to find out about information and care for yourForge Motorsport cooling product. The above dyno graph shows a Forge customer making gains of 52HP with this intercooler  5 / 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!   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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