FORGE intercooler for Hyundai i30N

Description

The FORGE Motorsport uprated intercooler is intended for fast road use and high performance tunes, especially in hot climates. The bar and plate core has over 129% more volume and over 71% more frontal area than the stock intercooler. The high flow cast end tanks were developed with Solidworks CAD and flow simulation (CFD). On the turbo side, the end tanks have an internal divider so the full volume of the stepped core is used. A fabricated ducting system is integrated into the design to improve cooling. The intercooler was engineered in conjunction with BTCC.

The inlet and outlet are enlarged to 65 mm, giving 27% more volume than the stock cooler. The kit includes a custom boost pipe that replaces the stock pipe on the hot side. Its diameter increases from 50 mm to 64 mm. Both the intercooler and the boost pipe have a black textured powder coat finish for longevity.

For dyno testing, the manufacturer let the car heat soak until the radiator fans cycled, which gives an inlet temperature of around 40°C. After more than six consecutive pulls, intake air temperature stayed at 24°C, compared with 48°C on the stock intercooler. The ambient dyno cell temperature was 15°C. At high intake temperatures the ECU retards ignition timing to prevent detonation, so power drops. On mapped vehicles, this can lead to premature engine wear. In the manufacturer's test, the intercooler raised power and torque from the claimed 275 bhp and 278 lb ft to 307 bhp and 347 lb ft.

Installation

The kit includes all necessary hardware. Installation takes approximately 2.5 hours, depending on experience and the tools available.

Specifications

• Type: front mount intercooler
• Core construction: stepped bar and plate
• Core volume: over 129% more than standard
• Frontal area: over 71% more than standard
• Inlet and outlet diameter: 65 mm
• End tanks: cast, internal divider on turbo side
• Boost pipe diameter: 64 mm (standard 50 mm)
• Finish: black textured powder coat
• Colour: black
• Manufacture: UK

Package Contents

• Intercooler
• Hot side boost pipe
• Ducting
• Mounting hardware

Suitable for

• Hyundai i30N