FORGE intercooler for Cupra Leon

Description

The FORGE Motorsport performance intercooler is designed, produced and tested at the manufacturer's headquarters in Gloucester, UK. The aim was to use all the available space in the OEM intercooler position and lower inlet air temperature without any negative effect on boost pressure or on engine and transmission cooling. The design also allows for future stage 3 and higher tunes. According to the manufacturer, the intercooler adds 11 bhp and 20 Nm and reduces intake air temperature by up to 58%.

The manufacturer tested several cores with different fin configurations and internal capacities. It chose a bar and plate core with over 83% more volume and 10% more frontal area than the OEM unit. The shape was designed using scanning and measuring and refined with flow simulation (CFD). The high flow baffled cast end tanks give smooth air transition and make use of the full internal volume of the core. The inlet and outlet are enlarged from the OEM 63 mm to 76 mm, a 45% increase in area.

The silicone hoses have an internal step, so the transition at the hot and cold side inlet and outlet junctions is seamless. This reduces airflow disturbance and turbulence.

Installation

Installation is plug and play in the original position, with no cutting of the vehicle.

Specifications

• Core construction: bar and plate
• Volume: over 83% more than OEM
• Frontal area: 10% more than OEM
• Inlet and outlet diameter: 76 mm (OEM 63 mm)
• End tanks: high flow, baffled, cast
• Power gain: 11 bhp (manufacturer's figure)
• Torque gain: 20 Nm (manufacturer's figure)
• Intake air temperature reduction: up to 58%
• Manufacture: UK

Suitable for

• Cupra Leon