Intercoolers

This front mounting intercooler kit has been designed as an upgrade for the Audi 2.0 TFSi (B8 models) and A5 2.0 TFSi. After extensive testing, we found that the most efficient core design for these models, was of a tube and fin construction, and along with an increase in surface area, plus an overall dimensional increase, we have been able to improve the cooling ability and reduce the pressure loss across our intercooler, when compared to stock intercooler. With testing conducted both on road and on the dyno, to ensure that this kit really worked, our results showed both a reduction in inlet temperature, an increase in horsepower and torque, but with no detrimental effect on lag or spool up time. The Dyno results gave a respectable +12hp and + 28 ft/lbs on a standard tuned engine, with increased benefits when software tuned.  The hoses used are available in red, blue, or black. Please select your colour choice in the options above when ordering.   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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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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Uprated front mounting intercooler for the VW T5 bus or van variants. Although significantly larger than the original intercooler, this unit is a direct plug in replacement requiring no additional hoses or pipework. With a larger front cross sectional area, the cooling/power recovery is improved. The unit offers a lower resistance, compared to OEM without adding turbo lag. On our own van we gained 10hp and 20 ft/lbs of torque with just the intercooler, and all who drive the vehicle since the installation have commented on how much better it feels. For those that have used a tuning box, or have updated engine management software, this really is a must. Stock Intercooler: 720x215x30 Forge Intercooler: 680x290x40   Fits the following engines: AXB, AXD, AXE, AXC, BRR, BRS, BNZ, BPC, BLU, CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB.   This will aslo fit the new 2010 onwards Vw T5.1  2.0TDI single turbo  140bhp, 114bhp, 102bhp, 84bhp models. Fitting Guides VW T5.2 VWT5   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 intercooler has been specifically designed for the VW T5.1 fitted with the twin turbo diesel. Using a combination of greater core size and thermal efficiency, we have been able to improve the cooling of the intake charge air, which in turn means more power when compared to the original intercooling, and may lead to greater longevity of engine components, as heat related stress is decreased. Our own test vehicle consistantly showed that our intercooler reduced the intake air temperature by a further 10°C when compared to the original intercooler, and had a lower resistance resulting in a pressure drop. This product would normally be recommended for those who have tuned the engine by using performance software or a tuning box type interceptor, but it may also aid fuel economy depending on driving style. *Please note that the oil cooler as displayed in the product images, which will help reduce temperatures further, must be purchased seperately.   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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As the preferred and official supplier of intercoolers to Mini Challenge, we are proud to present our intercooler for the Mini JCW F56 Chassis (2014-on). As the originators of the stepped core design way back in 2006, we were best placed within the market to call on our vast expertise in order to deliver a direct fit intercooler that would enhance the performance potential of the BMW Group 2.0 petrol turbo engine. Our core offers a 31% increase in frontal area over stock (BMW Part no.17517617600) and a correspondingly large increase in volume of 41%. Our end tanks are cast aluminium, made from 3D printed prototypes that we manufactured ourselves in our dedicated R&D facility in Gloucester, UK. The bar and plate design we have used comes after months of testing different core designs and opting for the core with best internal and external airflow. Official supplier to Mini Challenge The Forge F56 JCW intercooler gives a respectable 31% increase in frontal area over stock and a correspondingly large increase in volume of 41% The Forge F56 JCW Intercooler leaves the opposition behind yet again being the first to market The Forge development team have used Solidworks software to improve the OEM end tank design, making the Forge cast version a much freer flowing and efficient unit Testing and flow analysis has made this product a clear market leader Pressure drop under 1 Psi. This product is designed, developed and manufactured entirely in Great Britain and is covered by our lifetime warranty. Click here to find out about information and care for your Forge Motorsport cooling product. *Please note - this product does not fit the 2017 JCW cabriolet*   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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

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A set of 4 silicone hoses for the Volkswagen Mk5 Golf 2 Litre Turbo. The hoses, constructed from the highest grade European silicone and fabric reinforced, can withstand geater temperatures and pressures than the original organic rubber hoses. All Carbon Canister hoses are lined with a fluorosilicone rubber compound that gives protection against any oil or oil mist that may be present. Oil will degrade and discolour unprotected silicone hoses. The hoses are available in a choice of red, black, and blue, simply select your choice in the options above when ordering. The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone. This means the hoses are suitable to be used with  either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist. The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader. Lifetime warranty*   *T&C’s apply     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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*For the Veloster N intercooler, please click here* The Forge Motorsport front mount uprated intercooler for the Hyundai i30N. If you use a i30N for fast road or have a high performance tune in a hot climate, this product is essential. Utilising our industry leading bar and plate design alongside Solidworks CAD and flow simulation design (Computational Fluid Dynamics - CFD) to develop our high flow cast end tanks, the turbo side endtanks feature an internal divider to ensure the full volume of the stepped core is utilised.  The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge Motorsport intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skilfully integrated into the superior design of this product. The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm - up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune. The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity. During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C), we then did a dyno pull from this point, in doing this it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM. After more than six pulls on the dyno we still had super safe IATs and the Forge Motorsport intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear. This intercooler combined with our intake, and a quality aftermarket cat back exhaust will deliver you unparalleled levels of performance. The final testing results were very notable - not only did the Forge Motorsport intercooler halve the IATS, it also significantly increased both power and torque over Hyundai’s claimed figures of 275bhp and 278lb.ft of torque, making an extremely impressive 307bhp and 347lb.ft. The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available.     Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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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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