Intercoolers

An all alloy radiator for the Megane RS250/265/275. With the known coolant temperature issues that are attributed to the original fitment radiator, this is the only real solution. The stock Renault radiator has a major design flaw in that the inlet and outlet are in a straight line across the core. At high engine rpm, when you need the most cooling, the maximum flow is straight across the core, missing out about 75% of the volume. Worse still, the 25% of the core with good flow is directly behind the crash bar and gets no direct airflow. Our engineers have maximised the surface area and utilised a high efficiency radiator core with a unique flow enhancement, to ensure that the coolant passes evenly across the entire core, and that the area of restricted airflow (behind the crash bumper) is taken into account. Being confident in our design, we sent this for independent testing and were pleased to hear that they had achieved a reduction of 20°C in peak water temperatures,and also a drop of 15 °C in oil temperatures on the track.   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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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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This is a replacement for OEM part number 17517617598 Please note this product does not fit the Mini F57 JCW Official supplier to www.minichallenge.co.uk The Forge F56 intercooler gives a massive 64% increase in frontal area over stock and a correspondingly large increase in volume of 68%. Pressure drop under 1 Psi. CNC machined intercooler couplers to ensure a precision fit to the OEM Hose couplers. Supplied with all fitting hardware, and instructions no additional purchases necessary This intercooler is designed as a direct replacement for the OEM intercooler and requires no cutting of bodywork etc. This product is designed, developed and manufactured entirely in Great Britain and is covered by our Worldwide lifetime warranty. High flow cast end tanks to ensure optimum air transition for cooling efficiency Adds more aggressive styling to the front end. Provides a smoother power curve. The Forge intercooler for the F56 utilises a race specification Forge Alsus* designed air core. Dyno proven horsepower and torque gains Forge Motorsport are first to market with a full range of intercoolers for the Mini (Petrol) F56 Turbo range, 1.5 Turbo Cooper, 2.0 Turbo Cooper s and 2.0Turbo JCW. *Please note - this product does not fit the 2017 JCW cabriolet* Please look through the front grill to ascertain which cooler you need. The FMINT8 has 7 tubes the FMINTMF56 has 11 FMINT8 Or FMINTMF56                                                                                                                                                                                                                      Fitment of the core is involved but straightforward using the instructions that we provide, together with a full fitting kit. No cutting is required, this core simply replaces the original.     PLEASE NOTE: THIS WILL NOT FIT THE JCW MODEL.  FOR OUR JCW INTERCOOLER PLEASE VIEW FMINT7   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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

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*DOES NOT FIT AUTOMATIC CARS* Designed for the Fiat 500 Abarth T-jet, a front mounting intercooler with all associated hoses, pipes, and fittings, that replaces the existing side mounted intercoolers. This unit was developed to be suitable for those running standard turbos and ECU software (standard vehicle + 10 hp, +10 ft/lbs torque) and also those with larger turbo conversions. Whilst the factory set up using the two intercoolers in parallel is reasonably efficient, the removal of the long lengths of small-bore pipework, quickly lowers the circuit resistance, allowing you to benefit from the true capabilities of the turbocharger. Our development engineers have managed to increase the intercooler surface area by 100% and also increase the volume by 22%. This improvement along with sitting the intercooler at the front of the vehicle to maximise air flow and cooling efficiency, we really do have winner! This kit is available with red, blue, or black silicone hoses. Please select the colour required in the options above. NO CUTTING OF THE VEHICLE IS REQUIRED TO FIT THIS INTERCOOLER               Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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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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This front mounting intercooler kit has been designed as an upgrade for the Audi S4 B9 and fits the Audi A4 B9. Offering a huge 128% increase in frontal area and matching increase in internal volume the Forge intercooler is a must have for anyone tuning new twin-entry single turbo 3.0 V6 328bhp engine fitted to the latest in the line of high performance S4 Audi's. Utilising a race specification Forge Alsus* designed Bar & Plate construction and hand fabricated sheetmetal endtanks crafted at our fabrication facility in Gloucester, UK. The core measures 650 x 420 x 50mm. 128% increase in frontal area. 128% increase in volume. Black powdercoated finish. Supplied with high quality silcone hose, hose clamps, and fixings required for the installation.   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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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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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 as an upgrade Mini Countryman Cooper S models. After considerable trials with different intercoolers cores, we found that the most efficient for these models, was an intercooler of bar and plate design, and along with a significant overall increase in dimensions we have been able to improve the cooling ability and reduce the pressure loss across when compared to stock. Our own road and dyno testing showed that our intercooler was twice as efficient as the original intercooler with the inlet temperatures halved. The uprated intercooler is supplied with all parts required for the installation and comprehensive instructions.   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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