Intercoolers

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 the FMKT024 boost hose set if you so wish.

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.

This alloy tube is fitted with an alloy boss to accept the MAP sensors, as found on Audi, VW, SEAT, and Skoda (VAG) vehicles. The housing will fit the larger and smaller sensors, by using the size reducer supplied.

With our extensive development, we were very eager to use our wealth of knowledge to extract the best possible results from the Turbo charged Honda Civic Type R. Immediately we were able to 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 that Honda had failed to take advantage of.

This is a replacement for OEM part number 17517617598 Please note this product does not fit the Mini F57 JCW 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.

Forge Motorsport is proud to present our for the Mini Cooper 1.5 Turbo F56 Chassis. The core offers a 123% increase in frontal area over stock (BMW Part no 17517617597).

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 intercooler is a full replacement single pass (left to right) core which mounts to the stock crash bar in the car.

On the new 2.0 Litre FSIT engines, there is one sure way to improve on the charge air cooling by using the Forge "Twintercooler". This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band, beyond that of a single core setup. 

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.

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.

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.

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.

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.

We are pleased to release the Forge Motorsport intercooler for the Honda Civic Type R FK8. 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 features an internal divider to ensure the full volume of the core is utilised. 

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.

The Audi S1 packs the large 2.0 TSI engine from the Golf GTI into a small chassis, so some things are bound to be compromised, and unfortunately Audi decided to make do with in intercooler that’s around a quarter the size of the one found on the Golf! On a remapped car this easily pushed intake temperatures up above 80°C.

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.

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.

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.

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.

The new intercoolers are similar in dimension to the OEM units, but are measurably thicker. The real improvement came with the complete re-design of the intercooler core, after testing proved a bar and plate design to be more thermally efficient in this installation. In tests, the Forge unit managed creditable increase of 20hp. This installation allows the engine to produce more power and torque throughout the rev range, and of course with the engine running cooler, engine longevity should also be improved.

At Autosport 2005, Forge were proud to release our uprated Intercooler for the BMW Mini Cooper S. After a comprehensive development program involving thorough testing in various environments, we are convinced that you will not find a superior Intercooler for this application. 

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.

With the release of the new Porsche Macan turbo, our development team were eager to get on with the delivery of another industry leading intercooler. Utilising our extensive development knowledge with 23-years’ experience in the business, we were immediately able to increase the size of the core, allowing much more surface area and cooling efficiency than the stock core.

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. 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.

For the new 2.0 Litre FSIT engines, there is one sure way to improve on the charge air cooling by using the Forge "Twintercooler." This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

For the new 2.0 L FSIT engines there is one sure way to improve on the charge air cooling by using the Forge TWINtercooler. This innovation features our unique twin-intercooler design which has added greater efficiency throughout the entire RPM band beyond that of a single intercooler setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

Moving on from our tried and tested Twintercooler setup on the Mk5 and Mk6, this intercooler has been designed to run in parallel with the stock core, or if you prefer for the ultimate cooling solution you can use it with our FMMK7FMIC intercooler (which mounts in the stock location and offers much improved cooling by itself).  *This will not fit if your vehicle if it has Adaptive Cruise Control (ACC) radar sensor.

For the new 2.0 L FSIT engines there is one sure way to improve on the charge air cooling by using the Forge "TWINtercooler" this ground breaking innovation features our unique twin-intercooler design which has added greater efficiency throughout the entire RPM band beyond that of a single intercooler setup, We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures. We spent many months testing various designs and the Twintercooler design emerged as the clear winner.

This is a bolt-on kit that retains the use of the OEM intercooler to produce both horsepower AND torque, but more importantly, a HUGE reduction in inlet temperatures and increased flow efficiency. A reduction in temperatures of up to 19°C at 6500 RPM!

The latest VW Scirocco with the 1.4 TSI 160 (twincharged) petrol engine is now catered for with our market leading 'Twintercooler' - a design that runs our front mounted intercooler in parallel with the existing stock intercooler for amazing cooling power.

For the SEAT Leon 2.0 L and Leon Cupra 2.0 litre TFSI engines, there is one sure way to improve on the charge air cooling by using the Forge "twintercooler." This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

For the MK5 Golf GT, with the 1.4 litre TSi engine, we can offer a sure way to improve on the charge air cooling, by using the Forge "Twintercooler". Our ground breaking innovation, first proven on the 2 litre FSit engines, features our unique parallel intercooler configuration, which adds greater cooling efficiency throughout the entire RPM band, beyond that of a single intercooler setup, but without any perceived increase in turbo lag. Our data logging consistantly gave a reduction in temperature of up to, a peak of 9 degrees Centigrade.

Forge are pleased to present the Golf 2.0 L FSIT "Twintercooler" specifically for the Golf Edition 30. This kit uses our unique twin-core design which has added greater efficiency throughout the entire RPM band beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

The latest VW Scirocco R 2.0 TSI petrol engine is now catered for with our market leading 'Twintercooler' - a design that runs our front mounted intercooler in parallel with the existing stock intercooler for amazing cooling power. Giving a drop in ambient (cruise) temperatures of 5°C, and boosted drops of over 15°C, this is a sure way of keeping your inlet temperatures in check, even on chipped cars. Dyno testing has proved an increase in power and torque in even low ambient temperatures, with the maximum gains on chipped or reprogrammed ECU vehicles.

For the new 2.0L FSIT engines there is one sure way to improve on the charge air cooling by using the Forge "Twintercooler." This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

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.

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.

*Please note - This will not fit Audi S3 facelift 2017 onwards - Some modifcation to Audi S3 and TTS may be necessary* This is our intercooler for the Mk7 Golf, MK7R, Audi TT MK3 2.0 TSI and S3 (8V chassis) fitted with the EA888 2.0 TSI engine. Volkswagen group have changed just about everything from the Mk6 to the Mk7 chassis, so this core has had to be designed from scratch in order to fit in with the redesigned radiator and condenser.

This intercooler combined with The Forge intake, and a quality aftermarket cat back exhaust will deliver you unparalleled levels of performance.

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. 

With extensive development, and the continuing review of their intercooler for the TTRS, forge were very eager to use their wealth of knowledge to extract the best possible results with the RS3. Immediately they were able to increase the size of the core, allowing much more surface area and cooling efficiency than the stock core. the forge intercooler now uses up all the space the Audi had failed to take advantage of.

The engineers at Forge have developed this high performance tube & fin intercooler to replace the OEM intercooler found on the new VW T6 2.0 TSI. This van uses a derivative of the high performance “EA888” 2.0TSI engine found in the ever-popular Golf GTI.

This uprated intercooler replaces the original front mounted intercooler. It can either be used on its own or in combination with our "Twintercooler" kit. The intercooler uses a 650x400x50mm Bar and Plate core to full effect. We conducted testing on standard vehicles and those running larger turbos at 400hp.

Designed by Forge to replace your OEM intercoolers this all alloy intercoolers is an easy install. The Forge intercooler is 27mm x 5mm x 15mm bigger than the OEM - with excellent air flow characteristics inside the end tanks this upgrade is must.

Forge are pleased to present the all new Golf 2.0 L FSIT "Twintercooler." This ground breaking innovation features our unique twin-core design which has added greater efficiency throughout the entire RPM band beyond that of a single core setup. We have achieved this by using the latest core technology with high flow end tank designs to achieve a huge reduction in inlet temperatures.

The latest VW Scirocco with the 200PS 2.0 TSI petrol engine is now catered for with our market leading 'Twintercooler' - a design that runs our front mounted intercooler in parallel with the existing stock intercooler for amazing cooling power.