Intercoolers

With our extensive development, and the continuing review of our intercooler for the TTRS, we were very eager to use our wealth of knowledge to extract the best possible results with the RS3. Immediately we were able in increase the size of the core, allowing much more surface area and cooling efficiency than the stock core. Our intercooler now uses up all the space the Audi had failed to take advantage of. The core measures a massive 530x130x225mm, and is of bar and plate design. The end tanks are designed such that the standard boost hoses can be retained. To ensure that this monster is adequately supported we supply a genuine Audi crash bar, which we modify in house, which also eases the installation process. Total fitting time is only around 3 hours if you take your time, and can be fitted on a driveway if necessary. Rather than release this product immediately after development, we have taken our time with continued testing and tweaking, to ensure that we really have acheived the best possible. We have seen excellent results on both standard cars and those which have been remapped. In fact, on the standard car we had to repeat this several times because we just could not believe what we were achieving, and this presented us with a dilemma... we dont normally quote power figures as they can vary from car to car, dyno to dyno, and they are so variable with weather conditions, fuel used and even how much pressure you have in your tyres! However the gains were so good - on a standard car, with standard software, we saw peak gains of 40bhp in back to back testing. Does this mean that all cars fitted with this will get 40bhp ? Its impossible to say. We're merely including our results here as an indication of how well the core is working.     Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

Read more less

Forge has a well-established reputation for offering the best in chargecooler radiator upgrade kits for high-performance German vehicles - Audi S4 to Mercedes AMG A45’S. Using the knowledge gained in developing these uprated chargecooler radiators, we have used our proven testing and development procedure to develop an uprated kit for the Volkswagen T6 2.0TDI 180 & 204PS Transporter. The Forge all-aluminium construction chargecooler radiator offers extra reliability over the OEM type radiator with plastic endtanks that can fail with time. Maximising the available space behind the bumper of the vehicle the Forge chargecooler radiator offers a 50% increase in frontal area and a 50% increase in volume over the OEM. The radiator is a single pass design with inlet and outlet at diagonal opposites optimising the flow of coolant across the entire radiator core. Available in our highly durable stain black powdercoated finish. The kit is supplied with: 1x chargecooler radiator1x coolant hose kit2x billet aluminium hose couplerAll the necessary hoses clips and fixings   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.

Read more less

*Please note - this will not fit with Nightvision unless it is removed* Forge Motorsport Charge Cooler Radiator for the Audi RS6 C7 and Audi RS7 With modern day aftermarket ECU tuning pushing powerful engines harder. In certain conditions the vehicle will run the risk of receiving inadequately cooled air affecting the engines efficiency and ultimately losing power With this in mind Forge are proud to release the PolarCooler as the first auxiliary cooling system for the Audi RS6 and RS7 (C7 platform) cars in the market. Following exhaustive testing on the road and dyno working with 3 different manufacturers of water core, we are proud to present the ultimate in frontal water cooling solutions. The uniquely developed Forge PolarCooler features: An increase of over 100% extra capacity using a 22 fpi ( fins per inch )  louvre super tech cooling core for maximum  cooling. The PolarCooler retains the OEM charge cooler radiator but flows into a front mounted extra auxiliary radiator that is front mounted. This design means it has no obstructions i.e. the condenser to affect its efficiency and performance .It is not placed directly in front of the coolant radiator and is last in sequence. This unique design has allowed inlet temperatures to be lowered by 20 degrees C (68 degrees F) in 3 back to back consecutive runs on the dyno. With the Forge PolarCooler the standard bleed point is retained on the OEM radiator. The Forge  PolarCooler has no extra header tank as the  OEM  system utilises a one way valve within the system that only opens if the water level drops e.g. taking in water when it evaporates All of the Forge coolant hoses have been designed 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. 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 Forge PolarCooler comes complete with all the necessary hardware including an OEM modified crash bar and Forge silicon hoses to complete the installation, along with anti-corrosion black powder coat on the hand fabricated end tanks and crash bar.   This product is designed, developed and manufactured entirely in Great Britain and is covered by our Worldwide lifetime warranty. This Graph shows the vehicle without our chargecooler fitted:   This graph shows the results with our carge cooler fitted:   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.

Read more less

For the Audi S5/S4 3.0 litre Supercharged B8.5 Chassis ONLY, we have developed an uprated Charge Cooler Radiator and Expansion Tank kit. This kit is highly recommended for either those in warm climates who wish to maintain performance, or specifically for tuned engines where the boost has been increased from standard on the Eaton Supercharger using software re-calibration, a reduction pulley or a combination of both. To maximise the cooling efficiency we use an alloy fast thermal transfer radiator core which is 640 x 440 x 42mm. This has proven very effective in both keeping chargecooler temperatures lower but also reducing the recovery times in "heat soaked" situations   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.

Read more less

In addition to the Forge Motorsport PolarCooler range, here we have the top mount replacement chargecooler and expansion tank for the BMW MSport S55 Engine. The Chargecooler features an all aluminium construction which overcomes all the issues relating to plastic end tank splitting, failure at high boost and leaks between the core and end tanks with end tank seal failure. The end tanks are fabricated using high precision laser cut sheet metal panels which are TIG welded by hand for maximum strength and durability. Designed and manufactured at Forge Motorsport HQ in Gloucestershire, England, we utilised our Solidworks CAD design system to assist in the creation, modification, CFD (Computational Fluid Dynamics) analysis and optimization of this innovative charge cooler. Three different core constructions were evaluated during the development process. The final design of a bar and plate core far outperformed the other two alternatives. In doing this, the Forge Motorsport development engineers have made a quadruple pass design, allowing the water to flow through four passes of the cooler which improves the cooling efficiency beyond any other products currently on the market. Unique to the market, the Forge BMW M3/M4 S55 Chargecooler system (that also fits the M2 Competition F22 2018-) uses an expansion tank rather than a header tank like the OEM system. There is a filler cap located at the highest point on the Chargecooler allowing you to be sure that the charge is 100% full of coolant with no air pockets. This maximises the efficiency of the heat rejection of the coolant within the Chargecooler water jacket. Offering over 71% increase in volume and over 42% increase of frontal area. In hot climate testing, constant dyno runs showed significantly lower inlet temperatures compared with the stock system and an increase in power of up to 20BHP. As part of Forge Motorsport’s strict quality control process, each chargecooler unit is carefully inspected and pressure tested to 4BAR before despatch. Located on the outlet tank of the chargecooler there is also a 1/8 NPT port ready for water/methanol injection if required. The existing OEM Chargecooler rubber mounts are used for this expansion tank and Chargecooler, isolating the system from the harsh vibrations of the engine. No trimming or cutting of the vehicle is required and all parts can be returned to standard if necessary. In the box 1x Chargecooler unit1x Expansion tank with sight glass1x Expansion tank cap1x Small radiator cap1x Billet radiator cap cover1x Billet blanking cap1x 1/8 NPT Grub screw7x M6x12mm  Allen cap bolts7x 6mm washers1x M8x20mm Allen cap bolt1x 8mm washer1x M8 Nyloc nut3x 8-16mm Hose clamps1 x 8mm ID Vacuum hose x 170mm1x 8mm ID Vacuum hose x 750mm  Click here to find out about information and care for yourForge Motorsport cooling product.   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

Read more less

With modern day aftermarket ECU tuning pushing powerful engines harder, in certain conditions the vehicle will run the risk of receiving inadequately cooled air affecting the engines efficiency and ultimately losing power. With this in mind, Forge are proud to release the PolarCooler to enhance the auxiliary cooling systems on the BMW M3/M4 vehicles Building on lessons learned in developing our successful range of Audi and Mercedes chargecooler system upgrades, we have now designed this uprated chargecooler radiator for the BMW M3/M4. Available as a single item or for the ultimate cooling package to be use in conjunction with our Chargecooler and expansion tank kit - FMCC1 Offering a significant increase in core surface area and volume (545x460x32mm) Durable black powdercoated finish No cutting or trimming required to fit this product CNC machined couplers 1.7 Litre capacity Built in bleed point This product has a capacity of 1700ml or 0.449 US liquid gallon    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.

Read more less

While developing and testing our range of chargecooler radiators of Mercedes flagship A45 AMG, we took the time to develop a DSG oil cooler kit to reduce the high DSG gearbox oil temperature experienced under prolonged and high loads testing.    The large 13-row oil cooler is installed in the nearside lower bumper vent aperture that is unused on UK vehicles. This position allows optimum airflow to reduce oil temperatures. This kit has been re-engineered to fit face-lift Mercedes A45 AMG Models from 2016 onwards. Please note that the Pre-Face lift DSG oil cooler kit (FMDSG0C1) and Face-lift DSG oil cooler kit (FMDSG0C2) are not cross compatible due to the reprofiled bumper on later face-lift vehicles.   This kit is supplied with all the brackets and hardware required to install the 13-row oil cooler and CNC machined billet aluminium adapter plate.     Quality powder coated oil cooler housing bracket CNC machined and anodised adapter plate CNC machined and anodised banjo fittings Pre-assembled high-quality double braided AN-6 oil lines.       We recommend only using the correct Mercedes DSG oil to top up the gearbox (not supplied). If your vehicle year was manufactured between 2013-2015, (Pre-face lift) Mercedes A45 AMG please see product FMDSGOC1– DSG Oil cooler kit for Face-lift vehicles.     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.

Read more less

Working with in the limited space available surrounding the OEM side-mount chargecooler radiator and looking to develop the most efficient heat exchanger for the space available. Forge Motorsport has developed this compact V-mount radiator setup for the Mercedes A45 AMG (2.0L M133 Engine). Increasing the available core surface area by 43.5% over the OEM component. Featuring OEM style CNC machined couplers for direct fitment to the pre-existing chargecooler coolant pipework. No cutting of hoses or removal of couplers required. The laser cut radiator surround, clips into the OEM ducting and utilises the cold air feed from the front bumper. Refined design. This part has been carefully designed and developed using the latest Solidworks 3D CAD software. Researched, designed, developed, and handmade in Great Britain.   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.

Read more less

While developing and testing our range of chargecooler radiators of Mercedes Flag ship A45 AMG (Pre-Facelift), we took the time to develop a DSG oil cooler kit to reduce the high DSG gearbox oil temperature experienced under prolonged and high loads testing. The large 13-row oil cooler is installed in the nearside lower bumper vent aperture that is unused on UK vehicles. This position allows optimum airflow to reduce oil temperatures. This kit is supplied with all the brackets and hardware required to install the 13-row oil cooler and CNC machined billet aluminium adapter plate.  Quality powder coated oil cooler housing bracket CNC machined and anodised adapter plate CNC machined and anodised banjo fittings Pre-assembled high-quality double braided AN-6 oil lines. We recommend only using the correct Mercedes DSG oil to top up the gearbox (not supplied).   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.

Read more less

Developed from our direct involvement within the BTCC and Mini Challenge race series where we have provided race proven cooling packages, we have directly transferred our knowledge from this over to our road going products. FMOC11 has been developed with the same engineering expertise that is applied to our Mini Challenge Oil coolers, these see extensive driving over the race season calendar, so we are proud to give the I30N the same motorsport treatment. Lowering your oil temps on and off the track whilst providing a product that does not skimp on quality, so much so that it is backed by our Forge Lifetime Guarantee* With our extensive range of performance parts out on the market allowing the limits of the i30N/Veloster N to be pushed in the chase for top power gains, the addition of power and speed creates heat. Rising oil temperatures will result in only one outcome, a reduction of sufficient lubrication of your engines internal components. Therefore, the FMOC11 is a must have product for the keen driver, the location of the oil cooler radiator at the front of the vehicle’s radiator grill allows for superior air flow. During our development of this product we have seen oil temperatures reduced significantly. The Hyundai oil cooler has its inlet and outlets placed in the correct position for optimum flow , when oil coolers are fitted upside-down this can lead to cavitation (air locks) within the system, this can over a prolonged period of time lead to engine fatigue and potentially internal component damage due to insufficient engine lubrication. Unlike many oil cooler kits, the FMOC11 keeps the factory oil to water cooler in position. This essentially doubles your engines oil cooling. We’ve also developed the kit to use a bespoke laser cut aluminium bracket which makes for perfect fitment to the i30N crash bar. Supplied with the kit are 2x pre-assembled, high quality double braided AN-8 oil lines. We’ve incorporated a thermostat that is built into the oil cooler sandwich plate, this has been set to open at 85C as this was observed to be the optimal working temperature of the oil cooler when testing, this means the engine is working at its most efficient oil temperature range however hard you push the vehicle.   The kit comes with the following: 1x Forge Aluminium sandwich plate1x Twin pass oil cooler 4x M6x20 fasteners4x M6 washers2x Oil lines 4x M6 Rubber Riv nuts1X M20x1.5 adaptorAll the fixings 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.

Read more less

Product Description With modern day aftermarket ECU tuning pushing powerful engines harder. In certain conditions the vehicle will run the risk of receiving inadequately cooled air affecting the engines efficiency and ultimately losing power. With this in mind, Forge are proud to release another PolarCooler as the first auxiliary cooling system for the BMW B58 engine Found in the A90 Supra. Following extensive testing on the road and dyno working with 3 different styles of water core with different fin pitch configurations, we are proud to present the ultimate in frontal water cooling solutions. If you are a keen modifier and wish to push the limits of your A90 this chargecooler is a must, With 177% increase in volume hot climate owners will definitely appreciate the development that has gone into this product resulting in safer IATs (inlet air temps) for a longer period of time meaning when on track it takes longer for the standard ecu to reduce ignition timing which will create power loss. With the Forge PolarCooler it results in more power for longer with peace of mind for track day sessions.  The PolarCooler is available in either a powder coated satin Black finish or motorsport raw Alloy.      The uniquely developed Forge PolarCooler features: An increase of over 170% extra capacity using a 18 fpi (fins per inch) louvre super tech cooling core for maximum cooling. The PolarCooler replaces the OEM chargecooler radiator. This chargecooler has been designed featuring triple pass water flow to ensure all of the surface area of the core is utilised, meaning maximum cooling efficiency. This unique design has allowed inlet temperatures to be lowered by 20°C (68°F) in 3 back to back runs on the dyno. The Forge PolarCooler locates in the OEM position and is supplied with anti-corrosion black powder coat on the hand fabricated end tanks and core or motorsport raw alloy A reduction of the temperature of the cooling water is directly equated with an improved cooling performance of the charged air. With an increase in volume of water introduced to the cooling system the thermal temperatures can be kept at a much reduced level over a longer period, ensuring greater performance and efficiency which in turn is perfect for your fast road and track enthusiast. The Forge radiator has a volume of 23 litres compared to the OEM of just 8.3 litres. Dimensions:OEM:500mm x 615mm x 27mm  (8.3l)Forge Polarcooler:480mm x 600mm x 80mm  (23l) This product is designed, developed and manufactured entirely in Great Britain and is covered by our worldwide lifetime warranty. We estimate that it will take around 4-5 hours to complete installation of this product.

Read more less