Performance - Toyota Yaris GR (2020-Present)

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 Gains of 13bhp Peak torque gains of 8nm High quality carbon fibre Pleated performance air filter No engine management check lights (EML)  Increased air flow   Lifetime warranty* The Toyota Yaris GR has proven itself to be a fantastically capable vehicle since its release, and the development team at Forge Motorsport have been able to work their magic once again to find further improvements. After continued testing and discussions with owners of Yaris GR’s, the stock airbox has proven itself to function well, especially with the stock map. However, the weakness in the airbox is most definitely the quantity and directional flow of the air. As such, we explored several different avenues, before settling on a replacement upper airbox that mounts to the stock lower. When used in collaboration with the Forge Motorsport Inlet Duct (FMINLD1) performance car part, it ensures a consistent cold feed of air into the lower airbox that can then be delivered into a refined upper airbox. The increased diameter from 80mm of the stock inlet pipe to 89mm produces a volumetric increase of around 20% in just the connecting pipe from turbo inlet adapter to the airbox alone. After running data and tests it was decided that we would not use a panel filter, but instead a cone filter as shown in the CAD below. 3D scan data was utilised to ensure that the cone filter would fit in the optimum position inside the lower airbox, not just for ease of fitment but also to allow for optimum flow into the inlet tract. Due to the sensitivity of the MAF and stock map of the Yaris, a lot of testing was required to ensure that performance was gained without inflicting the driveability of the car - especially as we were changing from a panel filter to a cone filter and an increased diameter. To test this in real world conditions, we created a modular design that was 3D printed and allowed for different variations of MAF position, diameter, and airflow to be tested on road and the dyno. After finding the optimum design, we then reprinted the full prototype and left this on the vehicle. This allowed us to continue our testing to prove out the performance repeatability in real world driving conditions. We also noted at this stage that there is a small gain in induction noise. This product works extremely well when collaborated with existing Forge Motorsport performance products for the Toyota Yaris GR. With the release of our turbo inlet adapter (FMTIA8) we were able to increase the volumetric capacity over the stock inlet by 53%. Once coupled to this intake we have been able to ensure a smooth airflow from filter to turbo with minimal restrictions by continuing the 89mm diameter for a large proportion of the inlet tract. It is designed in a similar way to a conventional velocity stack by routing the air more directly into your turbo charger and allows more air to be compressed due to its larger capacity. This can have a positive effect on acceleration after long deceleration or in between gear changes due to more air being kept within the intake system. FMINDK43 is part of our acclaimed Hi Flow range and will ensure that your vehicle is getting critical cold air.  Not only are Forge Motorsport performance parts a better option for an improved drive, but carbon fibre car parts really help give an 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. Dyno Results We found that FMINDK43 with the stock turbo inlet produced peak gains on average of 13bhp at the wheels and peak torque gains of 8nm. The dyno graph below shows a comparison between the stock airbox, the 80mm prototype and 89mm prototype. We ran a total of 8 different prototype variations of MAF height, MAF distance from entry and inlet diameter to ensure that the best solution was used. You can see how sticking to the stock size diameter and MAF position with the cone filter produced a slight improvement to the wheel horsepower, however when increased to 89mm we were able to produce some fantastic gains from such an easy to install bolt on modification. Another important observation to note is where the power is delivered. As you can clearly see on the dyno graph that the engine produces a much higher power earlier into the rev range. From 2000rpm to 3600rpm the lower flap in the airbox is opened via a solenoid, and the dyno graph shows that at the same rpm there is an increase of around 15- 20nm of torque with FMINDK43 installed compared to stock. This figure is noticeable when driving, and you can feel that the vehicle picks up much better than in stock form. It’s worth remembering that this is with a stock ECU and no tune, so we would expect to see mapped cars returning even greater yields of power as they will be able to utilise the increase of airflow. The performance part kit comes complete with everything you need for installation, which can be carried out in around half an hour, including a set of full colour instructions. Our Toyota Yaris GR performance parts will help improve both the look and drive of your car. *Please note - the filter is excluded from the Forge lifetime warranty   

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Toyota Corolla GR - Yaris GR Gen 1 (2020-2024) Gen 2 (2024 Onwards) The Toyota Yaris GR and Corolla GR are both fabulous sporty hot hatches but there are still areas that can be improved upon. The gear shift is just one of those areas, the feel of the shift has a sporty feel however it is let down by the amount of travel in the gear stick. This short/quick shifter set has been developed by Forge to offer a crisp, short, and precise gear changing experience. Designed and developed by our highly skilled team on the Solidworks CAD system, the CNC machined billet linkage clamps onto a section of the original item to produce a pleasing shortened up and down shift. Our design enables full adjustment and reduced throw of between 40% and 60% which allows the customer to tailor the short shifter linkage to achieve the perfect gear change for their style of driving. The body of the shifter is manufactured from 6082 aerospace grade aluminium, then finished in black and red anodising for ultimate protection and durability. The machined stainless steel adjuster pin fits perfectly into the existing gear cable helping further to achieve a perfect shift. As with all our products, a set of comprehensive fitting instructions are supplied to enable fitting with no specialist tools in under a hour.    

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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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Product Description After discussions with many GR Yaris owners about airbox modifications, Forge Motorsport are proud to release the Toyota Yaris GR Inlet Duct. The Forge inlet duct allows you to add an aesthetically pleasing carbon fibre part to your Yaris GR’s engine bay and help keep your inlet temperatures down during spirited driving and whilst on the track or 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 performance car part is much larger than stock with a close fit to the front bumper and airbox to ensure that the heat from the engine causes minimal effect. 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. Data was collated and logged live by a passenger on a track day running in conjunction with an aftermarket intercooler on a 5 lap open pit session back to back against the stock inlet scoop (another 5 lap session). Inlet air temps had been reduced from 42°C to between 35 and 36°C. We even saw temperatures of up to 45°C on the stock duct. Fluctuation between temperatures on the stock inlet duct were greatly improved when air was fed to the secondary inlet scoop via the composite Forge Motorsport inlet feed. Please browse our Toyota Yaris GR performance parts today for other products in addition to this GR Yaris induction kit which you can fit to improve your track/rally experience. A Forge induction kit will unleash the power of your vehicle and help your engine breath. A recirculating or dump valve will be solution to the many failures that have occurred on the OEM part. With the OEM design including open sections, baffles, and noise restrictors to disrupt the airflow, the inlet duct is part of our acclaimed Hi Flow range and will ensure that your Yaris is getting critical cold air. Not only is the Forge part 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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State of art polymer laminated glass cloth Superb heat barrier qualities Withstands radiant temperatures up to 450°C/850°F Ultra thin for minimal clearance As used in WRC and F1 Each roll is 50mm wide x 5 metres long (2" x 16ft) Adhesive backing for ease of fitting After extensive market research Forge Motorsport are proud to release a state of the art metalized polymer laminated glass cloth with adhesive backing that is both extremely light and capable of handling continuous radiant temperatures of up to 450°C. It reflects up to 80% of all radiant heat, whilst offering weight savings against other heat reflecting materials. Forge Motorsport's gold reflective heat barrier requires minimal clearance and is an extremely pliable material with a pressure sensitive adhesive backing that is easy to apply and remove. As used in WRC and F1, make no mistake this gold reflective heat barrier tape is of excellent quality and superb value for money. When used correctly this tape can be used to protect intake components thus lowering IATs resulting in a more efficient and reliable engine cycle. Typical uses are: Wrapping wiring, inside engine covers, bulkheads and firewalls, boost pipes, fuel lines, under seats, intake pipes, airboxes, engine compartments, fuel cells…  

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Product Description This is a replacement carbon canister including Pipercross filter that fits the FMINDGOLR twintake and Fiat FMINDF500 These have been created exclusively for Forge by filtration gurus Pipercross, and feature the latest multilayer-foam technology that is proving to be so successful in this season’s British Touring Car Championship  (BTCC). These are priced individually. Please order 2 when replacing carbon canister/filters on the FMINDGOLR system. *Please note - the Pipercross filter is excluded from the Forge lifetime warranty* The filter should be installed with a maximum clamp torque pressure of 3nm.Please watch our video on how to fit an air filter without damaging it.  

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Product Description 70mm I/D Rubber Neck Open Cone Air Filter - High flow construction and increased surface area Replaces the filter in the following kits - FMINDK5- Ford Fiesta 1.0 Ecoboost induction kit FMINDST180- Ford Fiesta ST180 induction kit FMINDASTG - Astra G induction kit *Please note - this filter is excluded from the Forge lifetime warranty* Please watch our video on how to fit an air filter without damaging it.

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Product Description Hosetechnik are proud to release a high-performance 4 piece brake line set for the Toyota Yaris GR 1.6. These are a direct replacement/upgrade for the OEM brake line set and require no further modifications to fit. Each brake line is hand built in house at our workshops using only the best available 95PVC coated Stainless steel braided PTFE hoses and machined Stainless Steel end fittings resulting in a brake hose that will perform under the most extreme and harsh conditions, whilst still looking good and perform at the highest level. Our hoses eliminate all the problems associated with the original manufacturer’s rubber ones Immediate brake pedal response Lifetime Warranty Choice of colour Reduces pedal sponginess under hard braking Compatible with all brake fluids Will not corrode

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Now you can fine tune your Blow Off/Diverter Valve to the exact needs of your engine with this complete tuning kit. If you are finding that the valve is dumping more than required, or if you are losing boost pressure it is normally an indication that a stronger spring is required. Alternatively, if the valve is failing to dump it may be necessary to install a weaker spring. Please note that fitting a stronger spring into a valve will not increase boost pressure, unless existing pressure is being lost. Failure to allow the valve to operate by installing a spring which is too strong, may cause damage to the turbocharger. Please also note that the red coded springs should not be installed in the DVR or DV007 diaphragm valves.  Valve Spring color coding: Green - 5-15 PSI, Yellow - 15-23 PSI, Blue - 23-30 PSI, Red - 30 + PSI.*The above figures are estimates only and should only be considered as a guideline* Note: Serious or fatal damage may occur to the engine and associated components if this product is incorrectly matched to the individual engine requirements. Forge Motorsport nor any of it’s authorised distributors can assume any responsibility for any adverse effects resulting from the installation of this product.  Please contact us if you are uncertain whether this kit is suitable for your valve. *Please Note - The colours of the springs illustrated may differ to what you receive. All spring kits are brand new but are not sprayed. Colour is used as an identifier*   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.   FOR MULTIPLE VEHICLES 

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The Forge UNOS boost controller is a ball and spring CNC machined to aircraft grade specifications and incorporates a ratchet type top adjuster that will allow for the positive and precise adjustment that your driving style demands. The controller can be dash or engine bay mounted to suit your preference. This product is a universal component, and as such, no vehicle-specific fitting instructions can be provided. This product is designed and built with the intent of increasing the boost output of any forced induction system. We cannot guarantee compatibility with all applications, nor the ability to increase the boost output beyond a level that is within the parameters set by the engine-management-system of the given vehicle at the time of installation, whether that system is factory or aftermarket. Forge Motorsport nor any of it’s Authorized Distributors can assume any responsibility for any adverse effects resulting from the installation and tuning of this product onto a vehicle whose engine-management-system, whether factory or aftermarket, is not capable of allowing for the desired level of adjustment.   In The Box:1 x FMUNOS Boost Controller1 x Uprated Unos Spring2 x Unos Brackets2 x M4 x 8 Socket Cap Bolts1 x Forge Sticker   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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