Intercoolers

  Freshly developed at AIRTEC HQ in the UK, we’re proud to launch our ultimate specification intercooler kit with integrated crash bar design aimed at modified Toyota Yaris GR Gen 2 owners who want the very highest levels of cooling efficiency and performance for track or fast road use. The ChallengeOur earlier Stage 1 intercooler was developed to cater for tuned Yaris GR models of the time and has become a popular upgrade. However, Yaris GR tuning potential has since evolved and it became clear we would need a more substantial intercooler package better suited to big power, heavily tuned cars whilst future-proofing them for further tuning development. The SolutionAs a result, we developed the biggest intercooler kit we could and made the most of the available space behind the bumper by using a stepped core design that would rise up behind the entire front grille area. Using our experience in developing intercooler kits that integrate a replacement crash bar design, we were able to CNC machine billet brackets that allowed the intercooler to bolt in place. By doing so, the new intercooler offers a huge 143% increase in overall capacity in comparison to the original intercooler (54% bigger than our Stage 1 kit), and also features a colossal 115% increase in frontal area over standard (78% over our Stage 1), which allows it to make the most of the air flow provided. Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the Stage 3 AIRTEC Motorsport intercooler also features an enlarged 60mm inlet to match the outlet, and together the kit offers much greater efficiency and volume over both the standard and our Stage 1 intercoolers, which it proved during testing. Available in a high-quality powder coated black finish, the comprehensive kit is a direct replacement and comes complete with Pro Hoses silicone connectors to adapt to standard boost pipes – . It also comes complete with all fixtures and fittings, as well as detailed fitting instructions. To suit the Gen 2 model, the kit is also supplied with an extra mounting bracket to allow the original water spray system to be retained. A must have modification for those looking for only the very best for their modified Yaris GR models. The TestingDuring track testing at Snetterton Circuit in the UK using our 420bhp AIRTEC Motorsport development car, we logged the inlet and outlet temperatures of both our Stage 1 and Stage 3 intercoolers back-to-back. The figures showed that at this high level of power, over the course of a hot lap the Stage 1 starts to fight maintaining a stable charge temperature, with a 15-degree range highlighting its battle against the high and sustained levels of boost pressure. However, with the Stage 3 intercooler fitted, the figures showed the larger core with increased air flow provided a much more consistent charge temperature throughout the test, highlighted with just a 5-degree range in temperature. Verdict: Both intercoolers demonstrate a high level of efficiency, reducing charge air temperature by over 200 degrees and equating to over 90% efficiency, but the Stage 3 could sustain that level for longer, which is crucial for highly tuned cars to run safely for extended periods of time. T1 – TEMPERATURE INT2 – TEMPERATURE OUT Dimensions:OEM intercoolerWidth: 645mmHeight: 145mmDepth: 80mmCapacity: 7.5 litresFrontal area: 9,353cm² AIRTEC Motorsport intercoolerWidth: 610mmHeight: 330mmDepth: 110mm to 70mm stepped coreCapacity: 18.2 litresFrontal area: 20,130cm² Features: Specifically designed for the Yaris GR Gen 2 model Tried and tested to perform on heavily tuned cars 143% increase in overall capacity in comparison to original 115% increase in frontal area over standard Enlarged inlet pipe to 60mm Huge increase in cooling ability Incorporated crash bar design High-flow, moulded one-piece cast end tanks Gen 2 water spray system retained Powder coated black finish Includes fittings and fixtures Detailed fitting guide included   Please note: will NOT fit with AIRTEC Motorsport Oil Cooler (ATMSYGR04). Will fit with Stage 3 Oil Cooler (ATMSYGR14); now available.   AIRTEC Part No: ATINTYGR4

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Product Description With the release of the Gen 2 Yaris GR, we were quickly able to test fit our proven FMIC solution for the GEN 1 Yaris GR to this updated platform and achieved similar performance gains. However, due to the increased depth of the core used on FMINT25 over the OEM intercooler the water spray was no longer angled correctly to deliver effective cooling. The Forge Motorsport Water Spray Relocation Bracket angles the water spray nozzles to deliver the water mist as Toyota intended, allowing you to utilise the much-needed increased intercooler size over the OEM, combined with the enhanced cooling from the water spray to maximise results. Includes necessary hardware and instructions for installation Lifetime warranty

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Product Description Hand fabricated in the UK Simple installation  Gains up to 24BHP  35°C temperature drop 16 litre volume 640mm x 250mm x 100mm Genuine OEM crash bar supplied Guaranteed for life With our vast experience developing intercoolers for the last three generations of Audi RS3, we at Forge Motorsport have now used this experience and data to create a class leading intercooler for the Audi RSQ3 F3. FMINT38 builds on our reputation for delivering cores that offer real-world increases in power and temperature drops. Due to the RSQ3 using the legendary 2.5 TSFI engine used in the RS3 we knew that our intercooler design for that vehicle would work perfectly well on the RSQ3, however there are differences behind the bumper, so we have modified this kit to fit the F3 chassis perfectly. The core used for FMINT38 is a huge 640x250x100 and of bar and plate design. This gives it a huge 55% more surface area than OEM cooler, and an even more impressive 94% more volume (8.2 litres increased to 16l litres). 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 RSQ 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 finish powder coat for maximum longevity. 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 i.e. 22 ,17 or 12 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. 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. As shown in the graph below, for both tests we let the car heat soak 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 Forge Motorsport front mount intercooler has all the necessary hardware and comprehensive fitting instructions to install the kit in approximately 4 hours depending on competency and tools available.

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Designed to replace the original plastic trim grilles fitted to the outside of the bumper that leave the side radiators open and suspectable to road debris damage. These mesh grilles are made from 2mm laser cut aluminium and are finished in a high-quality black powder coat. They match the design of the centre grille mesh and offer much better protection for the expensive radiators.  They are a direct replacement and require no additional fixings, cutting or modifying to fit.  AIRTEC part no: ATMSYGR30

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As part of our expanding Toyota product range, AIRTEC Motorsport are proud to launch our Stage 3 oil cooler kit aimed at modified Yaris GR owners who struggle to maintain steady oil temperatures on track, or during fast road use. Developed in-house at AIRTEC HQ in the UK, this is our biggest oil cooler kit to date offering a huge 117% increase in volume over our Stage 1 oil cooler kit. Spanning across the entire front grille area for maximum air flow, the comprehensive kit also features laser-cut aluminium ducting to force cold air through the cooler. This allows it to fit with our Stage 3 intercooler kit (our Stage 1 oil cooler does not fit with the Stage 3 intercooler) to create the ultimate cooling package. Designed to fit both auto and manual transmissions, the package includes a large AIRTEC Motorsport oil cooler with ducting, bespoke laser-cut and powder-coated brackets, high-quality braided hose lines with Aerotec fittings, and all fixtures, including instructions, for a simple bolt-on installation. TESTED ON TRACKTried and tested on race tracks around Europe with our own 400+bhp Yaris GR, we were able to develop this package after battling with excessive oil temperatures when pushing hard for several fast laps in a row. As a result, our design engineers created a larger volume kit with carefully designed added ducting, which when tested created a huge improvement in sustaining safe oil operating temperatures no matter the climate, or period of driving. Key features: Suitable specifically for the Gen 2 Yaris GR – fits auto and manual transmissions Huge 117% increase in volume over our Stage 1 oil cooler Fits with our Stage 3 intercooler kit  to create the ultimate cooling package Full width oil cooler complete with cold air ducting Tested on track and proven to work Bespoke laser-cut and powder coated brackets High-quality hoses and fittings Comprehensive kit with all fixtures, fittings and instructions   AIRTEC part no: ATMSYGR31

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As part of our expanding Toyota product range, AIRTEC Motorsport is proud to launch our intercooler upgrade for the Yaris GR Gen 2, suitable for track or fast road use. Following on from the huge success of our Stage 1 intercooler for the Gen 1 model, we’ve created a package suitable for Gen 2 models with either automatic or manual transmission. The second generation Yaris GR uses a slightly different intercooler kit to the first generation cars in terms of fitting and the use of the water spray bar. Therefore in order to ensure there is no noticeable loss in performance during extended periods of hard driving on road or track, AIRTEC Motorsport has developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item. Our solution to increasing the intercooler’s size and performance is based upon our stepped-core design to make the most of the limited space available behind the bumper. The core steps from 110mm to 70mm and in doing so offers a huge 64% increase in overall capacity in comparison to the original intercooler. It also offers a 30% increase in frontal area over standard, which allows it to make the very most of the air flow provided. The inlet side of the intercooler retains a 50mm diameter to ensure minimal turbo lag whilst the outlet side increases to 60mm to offer less restriction. Together with our high-flow, moulded one-piece cast end tanks and an internal air diverter to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over standard. Despite this improvement, the kit fits neatly behind the original bumper and requires no trimming or cutting, and can be reverted back to standard with no issues. Designed to fit both auto and manual transmissions and includes a new bracket to mount the water spray bar. The comprehensive fitting kit includes all the correct fixtures and fittings, Pro Hoses silicone connectors as well as step-by-step installation instructions. The intercooler is available in a Pro-Series Black finish (with or without the AIRTEC logo) and gloss black Pro Hoses silicone connectors. Dimensions:Width: 610mmHeight: 195mmDepth: 110mm/70mm steppedInlet: 50mmOutlet: 60mm Features:  Suitable specifically for the Gen 2 Yaris GR – fits auto and manual transmissions 64% increase in capacity compared to original intercooler 30% increase in frontal area compared to original intercooler Huge increase in cooling ability Reduced charge temperatures High-flow, moulded one-piece cast end tanks Larger outlet pipe New bracket to mount water spray bar. Powder coated black finish All fittings and fixtures included Comes with detailed fitting guide AIRTEC part no: ATINTYGR3

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Delivering repeated cool intake air temperatures for your Audi RS3 8V.2 / 8Y or TTRS 8S EA855. Again and again and again. What it does.The factory intercooler on the Audi RS3 & TTRS has proved to be unable to cope with the demands of higher power, hard driven cars, showing up as serious power losses during hard driving as air temperatures soar. Our massive 'plate & bar' Intercooler System uses a stepped core to give a 70% volume increase over the factory cooler - making it one of the best performing intercooler upgrade on offer for the 2.5 TFSI. By consistently reducing intake air temperatures (IAT), heat soak is minimised delivering increased performance again and again. No need for the recovery cool-down times needed for the production intercooler. Our development focussed on finding the ‘sweet spot’ of maximum IAT cooling versus minimum pressure loss. This has allowed us to achieve increased size without increased lag.  Fitment is specific for the Audi RS3 8V.2 and 8Y - meaning no cutting or drilling is required to fit, and it's carefully designed to retain and fit around the car's original front crash bar. For TTRS, some trimming to the plastic front panel is required. MAXIMUM CORE SIZE The massive 'plate & bar' intercooler unit features a high-speed stepped core using extra tall internal tubes for maximum boost flow and a 76.8% increase in frontal area. SOPHISTICATED CORE Highly effective aluminium plate & bar construction, developed following rigorous testing to optimise core dimensions, fin density, and pipe flow providing a 70% volume increase. FLOWED END TANKS Cast construction end tanks for minimal turbulence and restriction use internal flow guides to divert airflow up and down across the entire core depth, with 70mm inlet & outlet. Confirmed Applications.2.5 TFSI EA855 engines (400ps)  Engine codes: DAZA, DAZC, DNWA, DXHA VWR143000 AUDI RS3 8Y 2021+ AUDI RS3 8V.2 2017-2020 AUDI TTRS 8S 2017+  * some trimming to front panel required Precision Engineered forPerfect Performance. OEM-fitment, requiring no drilling or cutting for perfect fitment on RS3. Giant core volume of 14,141,500mm³ vs 8,345,600mm³ for the factory cooler core. Don't confuse our 'Plate & Bar' construction with the cheaper and less-effective 'Tube & Fin' construction that most aftermarket intercoolers use. Intercooler outlets are 70mm - meaning stock boost pipes or our upgraded boost pipes can be used. Intercooler Performance.It's all about air intake temperatures. The OEM factory intercooler on the Audi RS3 & TTRS struggles with containing the all-important air intake temperatures once power is upgraded. So, intake air temperatures begin to rise rapidly, heat soak occurs, resulting in significant power losses the harder the car is used. The only way to recover the performance of the standard intercooler is to park the car for an hour. The RacingLine Intercooler makes a great difference in controlling IAT temperatures, meaning that your power increases keep on delivering, run after run.

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Delivering lovely cool intake air temperatures for your Polo GTI 2.0 TSI AW & AW.2. Again and again and again. What does it do?The factory intercooler on the Polo GTI AW has proved to be unable to cope with the demands of higher power, hard driven cars, showing up as serious power losses during hard driving as air temperatures soar. Our massive 'plate & bar' Intercooler System uses a stepped core to give a 56% volume increase over the factory cooler - making it the best performing intercooler upgrade on offer for the MQB-A0 platform Polo GTI AW. By consistently reducing intake air temperatures (IAT), heat soak is minimised delivering increased performance again and again. No need for the recovery cool-down times needed for the production intercooler. Our development focussed on finding the ‘sweet spot’ of maximum IAT cooling versus minimum pressure loss. This has allowed us to achieve increased size without increased lag.  Fitment is specific for the Polo GTI AW - meaning no cutting, drilling or modifications to the crashrequired to fit. MAXIMUM CORE SIZE The massive 'plate & bar' intercooler unit features a high-speed stepped core using extra tall internal tubes for maximum boost flow and a 25% increase in frontal area. SOPHISTICATED CORE Highly effective aluminium plate & bar construction, developed following rigorous testing to optimise core dimensions, fin density, and pipe flow providing a 56% volume increase. SMOOTH END TANKS Cast construction end tanks for minimal turbulence and restriction delivering maximum flow across the entire core depth, with 60mm inlet & outlet. CONFIRMED APPLICATIONSVWR141001 VW POLO GTI AW 2017-2021 VW POLO GTI AW.2 2021+ AUDI A1 40 TFSI GB 2017+ OEM-fitment, requiring no drilling or cutting for perfect fitment. Giant core volume of 10,039,737mm³ vs 6,440,000mm³ for the OEM core. Don't confuse our 'Plate & Bar' construction with the cheaper and less-effective 'Tube & Fin' construction that most aftermarket intercoolers use. Intercooler outlets are 60mm - meaning stock boost pipes or our upgraded boost pipes can be used. INTERCOOLER PERFORMANCE.It's all about air intake temperatures. The OEM factory intercooler on the Polo GTI 2.0 TSI struggles with containing the all-important air intake temperatures once power is upgraded. So, intake air temperatures begin to rise rapidly, heat soak occurs, resulting in significant power losses the harder the car is used. The only way to recover the performance of the standard intercooler is to park the car for an hour. The RacingLine Intercooler makes a great difference in controlling IAT temperatures, meaning that your power increases keep on delivering, run after run.

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Purpose-designed for the 2.0 TSI MQB 'Evo' engine, this is the largest-volume intercooler available for this platform. What it does.The factory intercooler on the 2.0 TSI MQB 'Evo' has proved to be unable to cope with the demands of higher power, hard driven cars, showing up as serious power losses during hard driving as air temperatures soar. Our massive 'plate & bar' Intercooler System uses a huge 70mm core to give a 96% volume increase over the factory cooler - making it the largest volume and best performing intercooler upgrade on offer for the 2.0 TSI gen.4. By consistently reducing intake air temperatures (IAT), heat soak is minimised delivering increased performance again and again. No need for the recovery cool-down times needed for the production intercooler. Our development focussed on finding the ‘sweet spot’ of maximum IAT cooling versus minimum pressure loss. This has allowed us to achieve increased size without increased lag.  Increased 70mm inlet and outlet sizes allow for higher flow versus the 60mm factory outlets, with matching Boost Hoses provided with the intercooler kit. Unlike most aftermarket intercoolers listed for the MQB 'Evo' platform, ours has been designed exclusively for the 2.0 TSI Gen.4 from the ground-up. MAXIMUM CORE SIZE The massive 'plate & bar' intercooler unit features a 70mm high-speed core using extra tall internal tubes for maximum boost flow and a massive 96% increase in volume. BOOST HOSES INCLUDED Internally-wired OEM fitment 70mm boost hoses are included, multi-ply to resist heat deformation and burst pressure. Supplied with stainless steel Mikalor-brand clamps. FLOWED END TANKS Cast construction end tanks for minimal turbulence and restriction use internal flow guides to divert airflow up and down across the entire core depth, with enlarged 70mm inlet & outlet. Confirmed applications. 2.0 TSI MQB Evo / EA888 Gen 4 engines only VWR141000 > VW Golf 8 & 8.5 GTI 2020+ > VW Golf 8 & 8.5 GTI Clubsport 2020+ > VW Golf 8 & 8.5 R 2020+ > VW Arteon 2.0 TSI EA888.4 2020+ > VW Arteon R 2.0 TSI 320ps 2020+ > VW T-Roc R 2.0 TSI EA888.4 2021+ > VW Tiguan II 2.0 TSI 245ps 2021+ > VW Tiguan II R 2.0 TSI 320ps 2020+ > Audi S3 8Y & 8Y.2 2020+ > Audi A3 2.0 TSI 8Y & 8Y.2 2020+ > Audi TTS 2.0 TFSI 8S 320ps (EA888.4) 2021+ > Audi TT 45 TFSI 8S 245ps (EA888.4) 2021+ > Audi SQ2 (facelift EA888.4) 2021+ > Cupra Leon 4 & 4.5 300 TSI FW 2020+ > Cupra Leon 4 & 4.5 245 TSI FW 2020+ > Cupra Ateca 300ps (EA888.4) 2021+ > Cupra Formentor 310ps 2020+ > Cupra Formentor 245ps 2020+ > SEAT Tarraco 2.0 TSI 245ps 2021+ > Skoda Octavia 4 & 4.5 vRS 2.0 TSI 245ps NX 2020+ > Skoda Superb III 3V 2.0 TSI (facelift EA888.4) 2021+ > Skoda Kodiaq vRS 2.0 TSI 245ps (EA888.4) 2021+   Precision Engineered forPerfect Performance. Giant core volume of 19,404,000mm³ vs 9,895,200mm³ for the factory cooler core Internal flow guides to optimise internal air flow via cast end-tanks Sophisticated 'Plate & Bar' construction outperforms the cheaper, less-effective 'Tube & Fin' construction Multi-ply, reinforced Boost Hoses are moulded with internal steps to maximise laminar airflow Intercooler outlets are 70mm vs 60mm for the OE cooler for increased flow Intercooler Performance.It's all about air intake temperatures. The OEM factory intercooler on the 2.0 TSI MQB 'Evo' struggles with containing the all-important air intake temperatures, especially once power is upgraded. So, intake air temperatures begin to rise rapidly, heat soak occurs, resulting in significant power losses the harder the car is used. The only way to recover the performance of the standard intercooler is to park the car for an hour. With a 70mm core-depth (vs 60-65mm for most other aftermarket intercoolers) and giant internal volume, the RacingLine Intercooler makes a great difference in controlling IAT temperatures, meaning that your power increases keep on delivering, run after run. Intercooler fitment. To accommodate the giant size of the RacingLine Intercooler, some light trimming of the black plastic radiator carrier is required.   This trimming is minimal on popular models such as the Golf mk8, but more may be required on some other MQB 'Evo' models.   For reference, fitment is designed for radiator carrier –  VW Part No. / 5H0 805 588 J

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Lower inlet air temperatures (IAT's) Massive increase of OEM part Extensively tested Easy install Prepreg 2x2 twill formed carbon fibre Lifetime warranty With the success of FMINLD1 for the Yaris GR we knew that there was a great opportunity to replicate the performance and aesthetic enhancement with the Corolla GR. The Forge Motorsport inlet duct fits the factory lower airbox and focuses on keeping your inlet temperatures down during spirited driving or while on the track/rally stage. By utilising 3D scans and SolidWorks CAD, our development team have been able to optimise the size of the inlet duct, creating an increase in uninterrupted cold air to be scooped into the stock airbox. 3D printed test parts were used alongside CAD simulation to ensure the optimum size and geometry. This inlet duct is much larger than stock, by replacing the entire shroud and effectively creating one large inlet duct to feed as much cold air into the OEM lower airbox. During testing on track days, the original duct caused inlet air temperatures to be heavily influenced by heat soak and fluctuated dramatically. Meanwhile the Forge Inlet Duct kept the inlet air temperatures not only reduced but at a more consistent temperature. A reduced consistent temperature is of great importance because any high temperature peaks will cause the ECU to retard the ignition and reduce the power you have available. The Forge inlet duct design incorporates a free-flowing path to both the upper and lower opening of the airbox, whereas the stock design has no flow management to the lower opening and the upper is small and not fully sealed. It is worth understanding that the lower opening is of far greater importance to the performance of your Yaris GR. There is a vacuum operated flap which is activated when under full throttle conditions, therefore the Forge Motorsport Inlet Duct ensures that your Yaris is getting colder directed air when the engine needs it the most. With the OEM design including open sections, baffles, and noise restrictors to disrupt the airflow, the Forge Inlet Duct is part of our acclaimed Hi Flow range and will ensure that your Corolla GR is receiving critical cold air. Not only is the Forge Inlet Duct a better option for performance, but the carbon fibre really helps to give the engine bay some character. The high-quality carbon fibre is prepreg 2x2 twill formed in an autoclave from billet tooling and finished with an anti UV gloss gel coat. 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.

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  As part of our expanding Suzuki product range, AIRTEC Motorsport is proud to launch our Swift Sport Boosterjet intercooler upgrade suitable for track or fast road use. In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item. The original intercooler is wide but shallow and significantly obstructed by the radar sensor and air duct, which are located directly in front of the intercooler core and restricts air flow. We concentrated on using the available space to create a core that fitted bedside the radar sensor but was much deeper. We then utilised the remaining space to produce a freer-flowing end tank design. The result is a core that’s a huge 80% deeper than the original, offering a massive 88% increase in overall capacity in comparison to the OEM intercooler and there’s also a significant increase in unobstructed frontal area, which allows it to make the most of the air flow provided. It’s also the only intercooler available on the market that offers 15% larger inlet and outlets, increasing to 60mm from the standard 52mm found on the original intercooler to reduce restriction. The kit is supplied with Pro Hoses silicone pipework, which joins to the OEM boost pipe on the outlet/cold side and replaces the pipework going to the inlet/hot side to further improve flow. We also offer an optional enlarged outlet/cold side pipe kit to match. Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater cooling efficiency and volume over standard. The kit fits neatly behind the original bumper and requires no trimming or cutting, and can be reverted back to standard with no issues. The comprehensive fitting kit includes all fixtures and fittings, as well as detailed installation instructions.  Dimensions:Original intercoolerWidth: 690mmHeight: 135mmDepth: 50mmCapacity: 4.66 litresFront area: 932cm²Inlet: 52mmOutlet: 52mm AIRTEC Motorsport intercoolerWidth: 570mmHeight: 170mmDepth: 90mmCapacity: 8.79 litresFront area: 978cm²Inlet: 60mmOutlet: 60mm Features:  88% increase in capacity compared to original intercooler Increase in frontal area compared to original intercooler Huge increase in cooling ability Reduced charge temperatures High-flow, moulded one-piece cast end tanks Larger inlet and outlets – unlike any other on the market Powder-coated black finish Pro Hoses silicone pipework Includes all fittings and fixtures Features detailed fitting guide Registered Design Right number: Application Pending  AIRTEC part no: ATINTSUZ2

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As part of our expanding Vauxhall platform product range, AIRTEC Motorsport is proud to launch our intercooler kit for the Astra CDTi 2.0, suitable for track or fast road use. In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item. Our solution to increasing the intercooler’s size and performance within the confines of the limited space behind the bumper is based upon a core design that is wider, taller and deeper.  This offers a huge increase in overall capacity in comparison to the original intercooler, as well as a substantial increase in frontal area over standard, which allows it to make the most of the air flow provided.  Together with our high-flow, moulded one-piece cast end tanks and air guide to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over standard. Available in a high quality powder coated black finish, the comprehensive kit is a direct replacement and comes with Pro Hoses silicone connectors, all fixtures and fittings, as well as detailed fitting instructions. Its improved cooling efficiency and easy fitment makes it an essential modification for all modified Astra CDTi 2.0 models. Dimensions:Width: 740mmHeight: 170mmDepth: 70mmCapacity: 8.8 litresFront Area: 1,258cm² Features: Huge increase in capacity and frontal area Improved cooling ability Reduced charge temperatures High-flow, moulded one-piece cast end tanks Powder coated black finish All fittings and fixtures included Comes with detailed fitting guide   AIRTEC part no: ATINTVAUX15

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  As part of our expanding BMW product range, AIRTEC Motorsport is proud to launch our replacement oil cooler kit for the E90, E92 and E93 M3 models, suitable for track or fast road use. With huge experience in developing external oil cooler packages for a variety of modified track and road cars, we chose to create a direct replacement oil cooler with a larger core to make the most of the space available in the original location.  As a result, our kit offers a huge capacity increase as well as improved cooling, thanks to a core that measures 79% bigger than the standard BMW oil cooler together with an increased frontal area of 17% over standard, which means there is more air flow passing through the core to help cool it.  The oil cooler attaches to the original oil lines and is supplied with new O-rings and replacement bolts as well as detailed fitting instructions for a simple installation process.   Features: Comprehensive kit designed specifically for the E9x M3 platform 79% larger core compared to standard  17% increase in frontal area compared to standard Improved capacity and oil cooling ability Direct replacement that fits in original location Reuses original oil line fittings Includes new O-rings and fixtures  Features detailed fitting guide AIRTEC part no: ATMSBMW17

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Our latest generation of high performance intercoolers take you to a new level of performance. With intercooler core dimensions of 2 x [270mm x 296mm x 115mm] and an impressive charge air volume of 18.4 liters, they offer an incredible 50% more airflow compared to the stock intercooler. In the process, the specially developed performance high-performance core provides superior cooling characteristics and won't let your engine down, even under extreme conditions. With a weight of just 9.0 kg per intercooler, we are setting new standards in lightweight design. The CAD-developed free-form end boxes made of high-quality cast aluminium guarantee optimum internal air flow and impressive pressure resistance of up to 6 bar (tested). Our reinforced silicone hoses and aluminium charge air tube provide excellent flow characteristics while maintaining high pressure resistance. In this way, we minimize back pressure and maximize the performance of your vehicle. To ensure long-lasting durability, all of our intercoolers feature a high-quality anti-corrosion coating with excellent heat conduction properties. This keeps your cooling at optimal levels at all times, and you'll benefit from a significant performance boost that will set you apart from the competition. Fitment: -Audi/Q8Our ready-to-install kit makes it easy to replace the stock intercooler - no complex modifications required. Because with us, every minute you spend on the race track counts. And to make sure you get only the best, all our products are subject to strict quality monitoring. Are you ready to take racing to a new level? Then choose the Competition intercooler and experience the power you deserve!Advantages of the Wagner Tuning intercooler:- improved cooling capacity- 18.4 liter charge air volume- weight per cooler 9 kg- less back pressure- +50% more air mass flow rate- Plug & Play* Adjustments to the original air duct necessarycore dimensions Stock intercooler:2 x [240mm x 296mm x 80mm]V = 11,4 LA = 1420 cm²core dimensions Wagner Tuning intercooler:2 x [270mm x 296mm x 115mm]V = 18,4 L (+65%)A = 1600cm² (+13%)+50% more air mass flowmuch better cooling performancePart number: 200001206:Kit comes with:2 intercoolers4 silicone hoses2 aluminium tubes1 mounting material1 assembly instruction

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Product Description-111% more volume than stock-Huge power gains-Up to 50% Reduction in IATS-Massive torque improvements-Replaces OEM 28270-2GT10-Fabricated in the UK-Guaranteed for life   Compatible Vehicles: Hyundai - Elantra - N 2022-   In collaboration with N Club Tennessee and Milltek Corp (Forge USA), we are excited to unveil a groundbreaking intercooler upgrade for the Hyundai Elantra N. Leveraging our industry-leading bar and plate technology, coupled with advanced SolidWorks CAD modeling and Computational Fluid Dynamics (CFD) simulations, While utilizing our wealth of knowledge and past experience developing industry leading products for Hyundai’s I30N on the Elantra N project we developed high-flow hand formed end tanks designed to optimize performance while making the most of the space available in the Elantra Ns chassis, enhancing both airflow and cooling capacity. The bar and plate core delivers an impressive 111% increase in volume and a 58% boost in frontal surface area compared to the stock cooler, making the Forge intercooler one of the largest and most effective upgrades currently available for the Elantra N. To further enhance the Forge Motorsportsintercoolers cooling efficiency, our team engineered a custom-fabricated ducting system that integrates seamlessly with the vehicle’s front bumper. This ensures perfect fitment and directs airflow precisely where it’s needed most.   The inlet and outlet sizes have been increased to 65mm, providing 27% more volume than the factory unit to optimize airflow. Additionally, we designed custom Silicone hoses to give the enthusiast a package that has seamless integration to the vehicles surrounding engine components. This complete package ensures maximum performance gains for vehicles at any tuning level. The intercooler is finished with our signature black textured powder coating, offering exceptional durability and longevity. Extensive testing of multiple core designs led us to select a high-quality bar and plate configuration, the same trusted design featured in our highly successful Audi RS3 and TTRS 8S intercoolers. The internal core design, fin shape and amount minimizes pressure drop while maximizing cooling efficiency, ensuring consistent performance gains under demanding conditions. 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 i.e. 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. 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. That’s why Forge Motorsport individually pick and test different core configurations ensuring the end user is delivered the best performing product. Our results speak for themselves. Inlet air temperatures (IATs) were reduced by half, unlocking significant performance improvements for tuned vehicles. During testing, we simulated real-world conditions by allowing the vehicle to heat soak on the dyno, with the radiator fans cycling on and off at an inlet temperature of approximately 40°C. From this baseline, dyno pulls demonstrated the Forge intercooler’s ability to deliver a much greater drop in temperature compared to the stock cooler. After six consecutive dyno pulls, the Forge intercooler maintained IATs of just 24°C - an incredible 50% reduction from the factory intercooler’s 48°C. These tests, conducted in a controlled 15°C ambient environment, highlight the stock intercooler’s inefficiency, which becomes even more pronounced in summer conditions. Elevated intake air temperatures can severely impact engine performance, causing the ECU to retard ignition timing to prevent detonation. This results in reduced power output and, in tuned vehicles, can lead to accelerated engine wear. The Forge intercooler ensures consistent cooling, delivering the performance and reliability you need to unlock your vehicle’s full potential. We would like to extend our heartfelt thanks to N Club Tennessee for their invaluable support and collaboration throughout this project. Their expertise and dedication were instrumental in bringing this exceptional product to life for the Hyundai Elantra N community. Together, we’ve created a solution that not only sets a new benchmark for performance but also underscores the spirit of innovation and excellence.

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New and Improved Design! We’re proud to launch our aluminium radiator upgrade suitable for standard or modified Fiesta ST150 models used for fast road or track use. Ideal for turbocharged or supercharged ST150 models, we well as dedicated track cars. With an increased core size of 45mm, our lightweight radiator solution features a tube-and-fin aluminium core together with lightweight aluminium end tanks. This design increases the cooling system’s capacity as well as improving its cooling efficiency, allowing it to retain lower running temperatures compared to an original unit after prolonged or hard use. It’s also suited to modified cars that operate with higher temperatures, or for hotter climate countries, where cooling can be an issue. Despite the increase in size, the radiator fits neatly in place and requires no modifications to fit, using the OEM mounts, fan and the original coolant connectors.  Features: Improved cooling efficiency Larger 45mm core design Increased capacity Lightweight aluminium construction Connects to original mounts and connectors Direct replacement with no cutting or trimming AIRTEC part number: ATRADFO11

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Lower IAT'sConsistent IAT'sMaximises airflow Perfect fit for FMINDF500OEM+ aestheticLifetime warrantyVehicle Fitment: Fiat-500-595        145BHP        Competizione 180BHP        Trofeo 160BHP        Turismo 165BHP -695        XSR Yamaha Limited Edition 165BHP       Rivale 180BHP To assist with the cold air feed to the scuttle on the Abarth 500/595/695 we developed an inlet duct which after testing in the crucible of motorsport, was found to keep a more consistent and lower IAT. With our Abarth induction kit (FMINDF500) also utilising the direct cold air feed to the scuttle panel, we knew that these race proven gains could provide a valuable addition to our ever-popular FMINDF500 Abarth 500/595/695 induction kit. Race Proven, Daily Driven isn’t just the Forge Motorsport mantra, but it’s also the way we look to develop our products. Our technical partnership with Mini Challenge has allowed us to test our Abarth 500/595/695 components within a highly competitive motorsport series and helps us to highlight areas to develop on other products. The Mini Challenge JCW class use a homologated Forge Motorsport intake, which utilises the cold air feed from the scuttle panel to maximise the density charge of air entering the turbo intake. FMINLD3 was developed specifically for RHD applications. Whilst it is compatible with the LHD scuttle panel, there is minimal functional benefit when fitted to LHD vehicles, due to a blank located directly beneath the designated mounting area. We are currently exploring the possibility of a template for quick and easy modification to the LHD scuttle, which would allow airflow to be channeled towards the induction inlet more effectively. If proven feasible, this template will be made available retrospectively to LHD owners. After valuable iterations of design, we settled for a solution that perfectly follows the contours of the scuttle panel to ensure a snug fit to capture as much cold air as possible. 3D-scanning, SolidWorks 3D CAD, and 3D printing gave us the ability to test the differences between width, height and fitment of the inlet duct to finish up with the perfect design to suit FMINDF500. By capturing the washer jet inside the inlet duct it allows for a much wider design to maximise airflow, and helps with installation. We have spared no expense as per usual with the manufacture of this design, by having billet injection mould tooling created to produce a part with an OEM+ aesthetic. By testing samples against the OEM scuttle panel, we have been able to match the mottled plastic finish so well that you would mistake it for being a factory component! The finishing touch was the gloss finish to the Forge Motorsport logo, making our world-renowned name stand out just enough to really compliment your tastefully modified Abarth. 

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As part of our growing range of VW products, Pro Hoses are proud to offer this four-piece boost hose kit for the Polo GTI 2.0 TSi AW model. No extra modifications required, a direct replacement of all four OEM hoses to fit with original  intercooler or AIRTEC Motorsport intercooler upgrade. Finished in gloss black only, these high-quality silicone Pro Hoses come complete with jubilee clips. Part No: PH/BOSVAG4

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As part of our expanding Audi product range, AIRTEC Motorsport is proud to launch our RS6 C8 intercooler upgrades suitable for track or fast road use. In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed larger capacity, freer-flowing intercoolers to replace the smaller and more restrictive OEM items. The original twin intercoolers are mounted between the bumper and inner arch liners and utilise designated air guides on both the front and back to help direct air to and from the intercooler effectively. Wishing to keep these in place, we opted to concentrate on creating a new core design that was the same width and height but deeper to help increase cooling ability. The result are direct replacement intercoolers that reuse all the original hoses, mounting points and air guides for simplicity but offer a huge 21% increase in overall capacity in comparison to the OEM intercoolers. Together with our high-flow end tanks to ensure internal flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler upgrades offer greater cooling efficiency and volume over standard.  The kit reuses all original fixings and includes detailed installation instructions for a simple and effective cooling solution.  TESTEDData logging of the turbo outlet/pre-intercooler temperatures and the post intercooler air temperatures showed the AIRTEC Motorsport uprated intercoolers maintained a steady rate with no abnormal spikes, despite the turbo temperature seeing a dramatic rise of nearly 170% in a short amount of time. In comparison, the original intercoolers were also logged and when the data overlaid, it highlighted they weren’t able to resist the temperature spike as well, seeing a rise of 60% over the AIRTEC intercoolers.    Features:  21% increase in capacity compared to original intercoolers Tested against original and proven increase in cooling ability Reduced charge temperatures High-flow, cast end tanks Powder-coated black finish Reuses all original mountings points and fixings Features detailed fitting guide Registered Design Right number: 6410583 AIRTEC part no: ATINTVAG47

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Now available from AIRTEC Motorsport, designed to suit the R53 Mini Cooper ‘Sidewinder’ turbo conversion kit from 1320 MINI, a complete ultimate cooling package! Price includes intercooler, radiator, all pipework and silicone hoses and Italian slimline fan along with fitting kit and brackets. Features: Track proven 60mm intercooler core Intercooler tube length 540mm, stack height 350mm Race spec core rated to 400bhp+ Track proven 40mm radiator core Radiator tube length 420mm, stack height 350mm Full height radiator, ideal for keeping temps low out on road and track – even in hotter climates! Comes with 9″ Italian made slimline sucker fan including mounting brackets and fixings Also includes full 60mm alloy hard boost pipes complimented by 60mm Pro Hoses silicone boost hoses Kit supplied with full fitting kit Available in Pro-Series Black or Natural Finish Silver Made to order Transform your R53 turbo build with one of our full cooling packages, designed to give you ultimate reliability in fast road and track applications around the world. *Please contact before purchase – kit is made to order with a lead time of 14 days.  Registered Design Right number: Application Pending. 

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Product Description Highlights: Peak gains of 17bhp Gains of 14lb/ft of torque 153% volume increase Hand fabricated in the UK Kit includes all necessary fittings and instructions included Lifetime warranty Following on from our very successful intercooler and performance products for the RS3 8V chassis, the Forge intercooler for the RS3 8Y chassis builds on our reputation for delivering cooling solutions, that offer real-world increases in power and impressive temperature drops. Whilst the 8Y chassis shares many components with the older 8V, 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 crash bar Audi has fitted to the RS3 8Y is made of steel, our Forge Motorsport intercooler kit utilizes a genuine Audi alloy crash bar, that we have cleverly modified in-house, in order to accept the enormous race intercooler. This in-turn when compared to the weight of the standard OEM intercooler and crash bar, is only 1kg heavier, meaning the additional weight has no detriment to performance and is far outweighed by the power gains achieved when it is installed. After our skilled fabricators have carefully crafted this piece of automotive artwork, we then finish both the crash bar and intercooler in our standard black finish powder coat for maximum longevity and that OEM+ look. The RS3 8Y core is a huge 640x250x130 with a bar and plate design. This gives it an impressive 55% increase in surface area over the stock OEM item, and an even more awe-inspiring 153% more volume. The end tanks are made with integrated pipes to retain the stock boost hoses, though you can also replace the standard hoses with our FMKT033 boost hose set if you so wish. This can help prevent hose expansion and failure when running increased boost pressures, just like on the 8V chassis. Before getting to work on the Dyno, we spec’d three different types 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. This is to ensure we deliver the best possible products for our customers, which is proven time and time again by one of the world leaders in the performance industry. 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 ,17 or 12 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 must work a lot harder to force the air through the core. This in-turn creates higher inlet air temps (IAT’s), as the turbo is creating more heat as it is working harder. 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 Testing Testing was completed independently 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 graph below shows the rolling road test for the OEM intercooler, for both tests we let the car heat soak 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. On the vehicle we used for testing and development, it made 424.9BHP and 382.9lb/ft. This vehicle was completely standard apart from being fitted with a Milltek cat back performance exhaust system. The measured power output is marginally more than the figures Audi quote, with a data logged peak intake temperatures of 43°C at 6550RPM. We then swapped out the OEM intercooler with the FMINT33 race intercooler to continue testing. The same car made 441.9BHP and 397.3lb/ft of torque with a peak recorded inlet temperature of 21.8°C at 6450RPM, this equates to a gain of 17BHP and 14lb/ft, and a drop of 22°C. Gains on mapped cars will likely be even more impressive as the stock intercooler core struggles on just stage 1 mapped cars, as previously found on the older RS3 that still uses the DAZA engine. From the independent testing and results pictured, you can see the intercooler really does deliver you unparalleled levels of performance. The Forge intercooler cools faster and delivers a far greater drop in temperature compared to OEM intercooler. The intercooler has all the necessary hardware and comprehensive fitting instructions to install the kit in approximately 4 hours depending on competency and tools available.

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Product Description Gains of 10bhp and 10lb/ft Temperature drops of up to 20°C Reduced turbo lag, increased response Greater overall surface area for greater heat dissipation Utilising a race specification tube and fin construction air core High flow cast end tanks ensuring optimum air transition for cooling efficiency A smoother power curve Volumetric increase of more than 100%, without additional lag Frontal area increase of over 40% Includes necessary hardware and instructions for installation Fits both Gen 1 and Gen 2 Yaris (select the water spray relocation bracket option if needed) Lifetime warranty If you have the Gen 2 Yaris GR with water spray option, you will need to select the additional bracket option. FMINT25 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.  

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As part of our expanding Suzuki product range, AIRTEC Motorsport is proud to launch our Swift Sport Boosterjet enlarged cold side boost pipe kit upgrade. Designed to work exclusively with our AIRTEC Motorsport intercooler upgrade, the enlarged cold side boost pipe kit replaces the pipework from the intercooler to the throttle body with a freer-flowing design that offers increased internal capacity to reduce restriction and improve response. The original pipework measures 50mm in diameter from the intercooler before stepping up to the 55m throttle body. We developed enlarged pipework that measures 60mm to meet the intercooler outlet and then continues throughout until it reduces down to the throttle body, offering a significant internal capacity increase of 20%. It also features fewer tight bends to further reduce restriction and improve flow. Made from high-quality aluminium, the pipework is finished in powder-coated black for a subtle OEM+ look and is joined with a Pro Hoses silicone pipe and connector. The installation package includes all fixtures and fittings, and detailed installation instructions. Please note: This kit will only fit with an AIRTEC Motorsport intercooler upgrade. Features:  20% increase in internal volume Larger and freer-flowing design Improves flow from intercooler to throttle body Increases throttle response  Direct replacement fitment Made from high-quality aluminium Powder-coated black finish Pro Hoses silicone pipework Includes all fixtures and fittings Features detailed fitting guide   Registered Design Right number: Application Pending  AIRTEC part no: ATMSSUZ2

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As part of our expanding Suzuki product range, AIRTEC Motorsport is proud to launch our Swift Sport Boosterjet intercooler upgrade suitable for track or fast road use. In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item. The original intercooler is wide but shallow and significantly obstructed by the radar sensor and air duct, which are located directly in front of the intercooler core and restricts air flow. We concentrated on using the available space to create a core that fitted bedside the radar sensor but was much deeper. We then utilised the remaining space to produce a freer-flowing end tank design. The result is a core that’s a huge 80% deeper than the original, offering a massive 88% increase in overall capacity in comparison to the OEM intercooler and there’s also a significant increase in unobstructed frontal area, which allows it to make the most of the air flow provided. It’s also the only intercooler available on the market that offers 15% larger inlet and outlets, increasing to 60mm from the standard 52mm found on the original intercooler to reduce restriction. The kit is supplied with Pro Hoses silicone pipework, which joins to the OEM boost pipe on the outlet/cold side and replaces the pipework going to the inlet/hot side to further improve flow. We also offer an optional enlarged outlet/cold side pipe kit to match. Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater cooling efficiency and volume over standard. The kit fits neatly behind the original bumper and requires no trimming or cutting, and can be reverted back to standard with no issues. The comprehensive fitting kit includes all fixtures and fittings, as well as detailed installation instructions.  Dimensions:Original intercoolerWidth: 690mmHeight: 135mmDepth: 50mmCapacity: 4.66 litresFront area: 932cm²Inlet: 52mmOutlet: 52mm AIRTEC Motorsport intercoolerWidth: 570mmHeight: 170mmDepth: 90mmCapacity: 8.79 litresFront area: 978cm²Inlet: 60mmOutlet: 60mm Features:  88% increase in capacity compared to original intercooler Increase in frontal area compared to original intercooler Huge increase in cooling ability Reduced charge temperatures High-flow, moulded one-piece cast end tanks Larger inlet and outlets – unlike any other on the market Powder-coated black finish Pro Hoses silicone pipework Includes all fittings and fixtures Features detailed fitting guide Registered Design Right number: Application Pending  AIRTEC part no: ATINTSUZ1

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