Intercooler for Hyundai i20N

This part replaces OEM part number 282702L000

The development team started with what they learned from the successful FMINT15 for the Hyundai MK3 i30N, as the 1.6-liter engine in the i20N shares the same design concept as the 2.0-liter in the i30N. Hand-fabricated end tanks as a starting point to create a mock-up intercooler, allowing them to understand the design parameters. This was then 3D scanned, allowing the development team to fine-tune and produce the biggest core with the smoothest flowing end tank design for the available space.

SolidWorks CAD and Computational Fluid Dynamics (CFD) were utilized to develop our high-flow cast end tanks. This helped incorporate a turbo side internal divider to ensure the total volume of the stepped core is utilized for maximum cooling. With the design completed, the end was 3D printed using Formlabs Form 3L printer to test fit to the vehicle and than to sign off the new design. To complete the development, they had one-off sand-cast end tanks manufactured, allowing to test the design before manufacture was started on the Forge Motorsport performance intercooler.

Highlights:

• Peak gains of 25bhp
• Gains of 43nm of torque
• Volume increase of 113%
• Hand fabricated in the UK
• Kit includes all necessary fittings and instructions included