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COMPATIBLE VEHICLES:Volkswagen - Golf - MK5 R32 Available in Black only A set of Silicone Coolant hoses for the R32 Mk5 Golf. Being modelled directly from the OEM hoses, these new precision engineered parts are an easy and direct replacement for the factory items, yet offer significantly greater ability to withstand much higher temperatures. Ideal on a standard car, but absolutely essential on a tuned, track or modified example! Allied to this, their superior woven fabric reinforcement and fluorosilicone internal lining, means that they will last an awful lot longer than the factory ever intended, too. Manual Gearbox cars only. The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone. This means the hoses are suitable to be used with  either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist. The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader. Lifetime warranty* Please note that two of the hoses will not fit the DSG models  

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Product Description-111% more volume than stock-Huge power gains-Up to 50% Reduction in IATS-Massive torque improvements-Replaces OEM 28270-2GT10-Fabricated in the UK-Guaranteed for life   Compatible Vehicles: Hyundai - Elantra - N 2022-   In collaboration with N Club Tennessee and Milltek Corp (Forge USA), we are excited to unveil a groundbreaking intercooler upgrade for the Hyundai Elantra N. Leveraging our industry-leading bar and plate technology, coupled with advanced SolidWorks CAD modeling and Computational Fluid Dynamics (CFD) simulations, While utilizing our wealth of knowledge and past experience developing industry leading products for Hyundai’s I30N on the Elantra N project we developed high-flow hand formed end tanks designed to optimize performance while making the most of the space available in the Elantra Ns chassis, enhancing both airflow and cooling capacity. The bar and plate core delivers an impressive 111% increase in volume and a 58% boost in frontal surface area compared to the stock cooler, making the Forge intercooler one of the largest and most effective upgrades currently available for the Elantra N. To further enhance the Forge Motorsportsintercoolers cooling efficiency, our team engineered a custom-fabricated ducting system that integrates seamlessly with the vehicle’s front bumper. This ensures perfect fitment and directs airflow precisely where it’s needed most.   The inlet and outlet sizes have been increased to 65mm, providing 27% more volume than the factory unit to optimize airflow. Additionally, we designed custom Silicone hoses to give the enthusiast a package that has seamless integration to the vehicles surrounding engine components. This complete package ensures maximum performance gains for vehicles at any tuning level. The intercooler is finished with our signature black textured powder coating, offering exceptional durability and longevity. Extensive testing of multiple core designs led us to select a high-quality bar and plate configuration, the same trusted design featured in our highly successful Audi RS3 and TTRS 8S intercoolers. The internal core design, fin shape and amount minimizes pressure drop while maximizing cooling efficiency, ensuring consistent performance gains under demanding conditions. 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 i.e. 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. 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. That’s why Forge Motorsport individually pick and test different core configurations ensuring the end user is delivered the best performing product. Our results speak for themselves. Inlet air temperatures (IATs) were reduced by half, unlocking significant performance improvements for tuned vehicles. During testing, we simulated real-world conditions by allowing the vehicle to heat soak on the dyno, with the radiator fans cycling on and off at an inlet temperature of approximately 40°C. From this baseline, dyno pulls demonstrated the Forge intercooler’s ability to deliver a much greater drop in temperature compared to the stock cooler. After six consecutive dyno pulls, the Forge intercooler maintained IATs of just 24°C - an incredible 50% reduction from the factory intercooler’s 48°C. These tests, conducted in a controlled 15°C ambient environment, highlight the stock intercooler’s inefficiency, which becomes even more pronounced in summer conditions. Elevated intake air temperatures can severely impact engine performance, causing the ECU to retard ignition timing to prevent detonation. This results in reduced power output and, in tuned vehicles, can lead to accelerated engine wear. The Forge intercooler ensures consistent cooling, delivering the performance and reliability you need to unlock your vehicle’s full potential. We would like to extend our heartfelt thanks to N Club Tennessee for their invaluable support and collaboration throughout this project. Their expertise and dedication were instrumental in bringing this exceptional product to life for the Hyundai Elantra N community. Together, we’ve created a solution that not only sets a new benchmark for performance but also underscores the spirit of innovation and excellence.

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Lower IAT'sConsistent IAT'sMaximises airflow Perfect fit for FMINDF500OEM+ aestheticLifetime warrantyVehicle Fitment: Fiat-500-595        145BHP        Competizione 180BHP        Trofeo 160BHP        Turismo 165BHP -695        XSR Yamaha Limited Edition 165BHP       Rivale 180BHP To assist with the cold air feed to the scuttle on the Abarth 500/595/695 we developed an inlet duct which after testing in the crucible of motorsport, was found to keep a more consistent and lower IAT. With our Abarth induction kit (FMINDF500) also utilising the direct cold air feed to the scuttle panel, we knew that these race proven gains could provide a valuable addition to our ever-popular FMINDF500 Abarth 500/595/695 induction kit. Race Proven, Daily Driven isn’t just the Forge Motorsport mantra, but it’s also the way we look to develop our products. Our technical partnership with Mini Challenge has allowed us to test our Abarth 500/595/695 components within a highly competitive motorsport series and helps us to highlight areas to develop on other products. The Mini Challenge JCW class use a homologated Forge Motorsport intake, which utilises the cold air feed from the scuttle panel to maximise the density charge of air entering the turbo intake. FMINLD3 was developed specifically for RHD applications. Whilst it is compatible with the LHD scuttle panel, there is minimal functional benefit when fitted to LHD vehicles, due to a blank located directly beneath the designated mounting area. We are currently exploring the possibility of a template for quick and easy modification to the LHD scuttle, which would allow airflow to be channeled towards the induction inlet more effectively. If proven feasible, this template will be made available retrospectively to LHD owners. After valuable iterations of design, we settled for a solution that perfectly follows the contours of the scuttle panel to ensure a snug fit to capture as much cold air as possible. 3D-scanning, SolidWorks 3D CAD, and 3D printing gave us the ability to test the differences between width, height and fitment of the inlet duct to finish up with the perfect design to suit FMINDF500. By capturing the washer jet inside the inlet duct it allows for a much wider design to maximise airflow, and helps with installation. We have spared no expense as per usual with the manufacture of this design, by having billet injection mould tooling created to produce a part with an OEM+ aesthetic. By testing samples against the OEM scuttle panel, we have been able to match the mottled plastic finish so well that you would mistake it for being a factory component! The finishing touch was the gloss finish to the Forge Motorsport logo, making our world-renowned name stand out just enough to really compliment your tastefully modified Abarth. 

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Developed, designed, and influenced from our direct involvement with BTCC and success with the Hyundai i30N, we are proud to release an oil cooling solution for the Hyundai Kona N. This oil cooler radiator is lifted straight from our motorsport department, so we know that this product performs well, and has been proven in several race events and winning vehicles over the past years. The cores are durable enough to last full race seasons and are perfect for fast road and track use. The cooler has now also been utilised in both of our other Hyundai oil cooling solutions and cleverly redesigned for a 100% plug and play solution for the Kona N. During our time developing world leading products for the Kona N, we found a significant flaw with the vehicle, especially when tuned, just as we did with the I30N. Oil temperatures can climb to dangerous levels when on track or when driven hard in hotter climates. Rising oil temperatures will result in only one outcome: a reduction of sufficient lubrication of your engines internal components, which, in due course, can potentially lead to engine damage. We saw oil temperatures reduce significantly during the development of this product when locating the oil cooler heat exchanger at the front of the vehicle’s radiator grill, this allowed for superior air flow. FMOC14 is a must-have product for the keen driver to protect their vehicles longevity, and perform safely and reliably. Unlike many oil cooler kits on the market, FMOC14 keeps the factory oil to water cooler in position - this essentially doubles your engines oil cooling. This product is not to be confused with a universal oil cooler, FMOC14 has a laser cut aluminium bracket which makes for perfect fitment to the Kona N. The kit is completely bespoke for this vehicle, with perfect length braided oil lines and our intelligent sandwich plate design making for a straightforward installation. The oil cooler is also designed to be mounted in the most efficient way possible as shown in the diagram below. This is to avoid oil cavitation which can also in some cases lead to potential engine damage over a long period of time. Manufactured in Gloucester, UK, FMOC14 is made to the uppermost standard and is backed up by the Forge Motorsport lifetime warranty. The kit comes with the following:1x Forge Aluminium sandwich plate1x Twin pass oil cooler 4x M6x20 fasteners4x M6 washers2x Oil lines 4x M6 Rubber Riv nuts1x M20x1.5 adaptor1x weather stripAll the fixings required and a comprehensive fitting guide

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Product Description Highlights: Peak gains of 17bhp Gains of 14lb/ft of torque 153% volume increase Hand fabricated in the UK Kit includes all necessary fittings and instructions included Lifetime warranty Following on from our very successful intercooler and performance products for the RS3 8V chassis, the Forge intercooler for the RS3 8Y chassis builds on our reputation for delivering cooling solutions, that offer real-world increases in power and impressive temperature drops. Whilst the 8Y chassis shares many components with the older 8V, 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.   The crash bar Audi has fitted to the RS3 8Y is made of steel, our Forge Motorsport intercooler kit utilizes a genuine Audi alloy crash bar, that we have cleverly modified in-house, in order to accept the enormous race intercooler. This in-turn when compared to the weight of the standard OEM intercooler and crash bar, is only 1kg heavier, meaning the additional weight has no detriment to performance and is far outweighed by the power gains achieved when it is installed. After our skilled fabricators have carefully crafted this piece of automotive artwork, we then finish both the crash bar and intercooler in our standard black finish powder coat for maximum longevity and that OEM+ look. The RS3 8Y core is a huge 640x250x130 with a bar and plate design. This gives it an impressive 55% increase in surface area over the stock OEM item, and an even more awe-inspiring 153% more volume. The end tanks are made with integrated pipes to retain the stock boost hoses, though you can also replace the standard hoses with our FMKT033 boost hose set if you so wish. This can help prevent hose expansion and failure when running increased boost pressures, just like on the 8V chassis. Before getting to work on the Dyno, we spec’d three different types 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. This is to ensure we deliver the best possible products for our customers, which is proven time and time again by one of the world leaders in the performance industry. 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 ,17 or 12 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 must work a lot harder to force the air through the core. This in-turn creates higher inlet air temps (IAT’s), as the turbo is creating more heat as it is working harder. 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 Testing Testing was completed independently 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 graph below shows the rolling road test for the OEM intercooler, for both tests we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 36°C), then do a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. On the vehicle we used for testing and development, it made 424.9BHP and 382.9lb/ft. This vehicle was completely standard apart from being fitted with a Milltek cat back performance exhaust system. The measured power output is marginally more than the figures Audi quote, with a data logged peak intake temperatures of 43°C at 6550RPM. We then swapped out the OEM intercooler with the FMINT33 race intercooler to continue testing. The same car made 441.9BHP and 397.3lb/ft of torque with a peak recorded inlet temperature of 21.8°C at 6450RPM, this equates to a gain of 17BHP and 14lb/ft, and a drop of 22°C. Gains on mapped cars will likely be even more impressive as the stock intercooler core struggles on just stage 1 mapped cars, as previously found on the older RS3 that still uses the DAZA engine. From the independent testing and results pictured, you can see the intercooler really does deliver you unparalleled levels of performance. The Forge intercooler cools faster and delivers a far greater drop in temperature compared to OEM intercooler. The intercooler has all the necessary hardware and comprehensive fitting instructions to install the kit in approximately 4 hours depending on competency and tools available.

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  Product Description Gains of 10bhp and 10lbft 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 Dyno proven horsepower and torque gains 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 Lifetime warranty 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 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 This kit comes as a set of four boost hoses for the Audi RS3 8Y with the DNWA engine codes. These include pre and post intercooler hoses, turbo outlet and throttle body elbow hose. The Forge silicone hoses in this kit are Fluorosilicone lined to prevent oil vapour penetration throughout the inner hose wall. Fluorosilicone lining also renders the kit suitable to be used with either modern long-life coolants, or Organic Acid Technology coolants (O.A.T.). The use of a Fluorosilicone lining ensures that Forge silicone hoses are the clear market leader. This durable Forge Motorsport silicone hose kit has been designed to withstand pressures experienced in both tuned and remapped Audi RS3 engines. This hose kit is covered by the Limited Lifetime Forge Motorsport Warranty, keeping you on the road and ahead of the pack!   This set of hoses is available in a black finish for that OEM look.      

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Product Description Following the success of our FMINT15 for the Hyundai MK3 i30N it was only obvious we should further development on the face lift MK3.5, with only a few minor design tweaks our plug and play solution is now available for the latest of Hyundai’s revision. With Hyundai redeveloping the turbo charger to run more boost and a larger flow than the previous generation there is even more reason to replace more restrictive OEM intercooler with the larger Forge Motorsport item, based on a stage 2 ECU calibration and fitted with the Forge intake (FMINDK28) and turbo inlet adaptor (FMTIA10) the new intercooler performed as expected, As you can see from the dyno results below, power was increased from 358 bhp with the stock intercooler and intake, to 381.2 BHP and 371.4LB/FT of torque with the Forge Motorsport parts installed. The Forge intercooler helps keep the IATS a safe level and prevent the stock ecu from pulling out the engines timing resulting in a loss of power. If you use a i30N for fast road or have a high performance tune in a hot climate, this product is essential. 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 feature an internal divider to ensure the full volume of the stepped core is utilised.  The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge Motorsport intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skillfully integrated into the superior design of this product. The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm - up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity. During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C), we then did a dyno pull from this point, in doing this it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM. After more than six pulls on the dyno we still had super safe IATs and the Forge Motorsport intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear. This intercooler combined with our intake, and a quality aftermarket cat back exhaust with factory software will deliver you unparalleled levels of performance. The final testing results were very notable - not only did the Forge Motorsport intercooler halve the IATS, it also significantly increased both power and torque over Hyundai’s claimed figures of 275bhp and 278lb.ft of torque, making an extremely impressive 307bhp and 347lb.ft. The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available

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Product Description We are pleased to present the Forge intercooler for the Veloster N facelift including DCT *If you use a Veloster N for fast road or have a high performance tune in a hot climate this product is essential* Utilising our industry leading bar and plate design, alongside Solidworks CAD and flow simulation design (Computational Fluid Dynamics CFD) we developed our high flow cast end tanks. The turbo side endtanks feature an internal divider to ensure the full volume of the stepped core is utilised. The bar and plate core has over 129% more volume and an increase of frontal surface area over 71% (over the stock cooler) meaning the Forge intercooler is the largest currently available on the market. To ensure we deliver optimum cooling efficiency, the development team created a fabricated ducting system that has been skilfully integrated into the superior design of this product this ensures fitment to the inner contour of the Veloster N front bumper. The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the stock cooler to give perfect flow. The development team also added a custom hard pipe increasing the diameter by 14 mm to 64mm up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity. Various core designs where tested in the development of the Veloster N intercooler with us finally deciding to use a high-quality Bar and Plate design as used on our highly successful Audi RS3 and TTRS 8s intercoolers resulting in minimal pressure drop. The results were fantastic with IATS (inlet air temps) being reduced by half and resulting in tremendous gains on tuned vehicles. During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C). We then did a dyno pull from this point. By doing this, it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM. After more than six pulls on the dyno we still had super safe IATs and the Forge intercooler gave results of 24°C, halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions with an ambient dyno cell temperature of 15°C proving how inefficient the stock intercooler is. In the summer months the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle the results will be even more detrimental and can lead to possible premature engine wear. The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available.  

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Product Description Highlights: 16bhp Gains 20nm increase in torque\ 24°C temperature drop  Made in the UK Reduced turbo lag No cutting of vehicle to fit Lifetime warranty This part will replace the following OEM parts: 5Q0145803H, 5Q0145803K, 5Q0145803L, 5Q0145803P, 5Q0145803S, 5Q0145803N Following on from our previous intercooler solution for the MK7 golf and MQB chassis variants that utilise the EA888 2.0 GEN3 2.0 TSI engine, we have designed our race intercooler to further enhance performance over the original intercooler and our previous iteration of our cooling solution, designed, developed and tested, at our headquarters in Gloucester UK. Throughout the development process we have strived to improve the efficiency and performance of the EA888 GEN3 engine. Our project brief was to develop an intercooler that utilised all of the available space in the original position of the OEM intercooler along with increasing the size again over our hugely successful product FMMK7FMIC. We also had to ensure the inlet air temperature is reduced, without any negative effects on the boost pressure or engine and transmission cooling. In the MQB chassis the intercooler housing is particularly restricted and confined to a small amount of space, due to it not only housing the intercooler, but also the radiator and air conditioning condenser. The front panel in theory is a sandwich pack that houses the auxiliary cooling components. This means in order to increase the size of the intercooler without paying detriment to the performance of the surrounding items, and with also having very little extra space available, that it can be very difficult to execute the perfect blend of a high flow intercooler within such a close proximity. Our research and development engineers went back to the drawing board looking at previous documented dimensions while also taking new scans of the intercooler housing, this enabled the team to squeeze a further 10mm in depth of the core that houses very snugly into the earlier MQBs platform. We also looked at the differences between the Mk7 and Mk8 cooling components and found that the Mk7 Golf GTI and Golf R has a thicker radiator than the MK8 equivalent models thus meaning we also needed to consider any fitment procedures carefully. The design team started to 3d print the intercooler end tanks while creating a test sample dummy core to fit to the Mk7s platform and check for any clearance issues that may occur. The final chosen design has increased inlet and outlet sizes along with increasing the volumetric capacity to increase flow which aids with future proofing the design to work well with highly tuned stage 3 plus EA888 Gen 3 engines as well as offering the best cooling solutions for either a stock or mildly modified powerplant. This gives the best package for the enthusiast as they start their journey in enhancing the vehicles performance. The 3d printed end tanks and dummy core enabled us to ensure the fit was perfect on the vehicle before any prototype castings or machined billet end tanks were produced ready for dyno testing. Several baffle configurations were designed, and flow simulated to ensure the maximum performance was obtained to keep the core working at its optimum, along with ensuring all its cooling capabilities had been upheld, and that the total volume of the core internal is utilised for optimum performance. With an increase in inlet and outlet sizes, we then turned our attention to the design of our silicone hoses. With flow in mind, we have created a step within the hose so where the hose meets the hot and cold side of the inlet and outlet junctions the transition is seamless, this helps to lesson any disturbance to the airflow and prevent unwanted turbulence. To further aid with flow, the inlet and outlets have been increased to 76mm from the OEM size of 63mm which equates to a 45% increase in surface area. The consideration of space and our clever design has led us to produce several intercooler cores with different fin configurations and internal capacities. Depending on the core design, testing results led us to choose a bar and plate design with over 83% more volume than the OEM intercooler, and with a frontal area increase of 10%. 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 i.e. 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. 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 using Performance Remap in Gloucester with their VTEC 4-wheel drive dynamometer; this was to ensure all our data has been achieved with results as accurately as possible by an independent tuner. Peak power was increased from stock by 16bhp and 20nm of torque at 5500RPM with the Forge Motorsport performance intercooler installed. The best news is that there are significant torque gains throughout the rev range, meaning that the car power will pick up quicker and pull the whole way through to redline, including an impressive gain in BHP increase from 5000 RPM TO 6500 RPM. Gains on vehicles with re calibrated software and further hardware performance parts can be expected to be a lot higher due to the substantial drop in IATS when FMINT32 is installed.     During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C), we then did a dyno pull from this point, in doing this it gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM. After more than six pulls on the dyno we still had super safe IAT’s, and the Forge Motorsport intercooler gave results of 34°C @ 6000 RPM giving a reduction of 58% over the factory’s intercooler intake temps from 58°C just before the rev limiter These tests took place in relatively hot conditions with an ambient dyno cell temperature of 23°C proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear. If you use a Golf R for fast road or have a high-performance tune in a hot climate, this product is essential.      Why do we try to reduce IAT's (Inlet Air Temperatures)? Temperature and volume of air supplied to your vehicles engine that is compressed by the turbo charger has a better effect on performance when cool as this is to provide the engine with more oxygen (denser air), thus improving the combustion in each cylinder. In addition, by regulating and reducing the air temperature, it also increases the reliability of an engine by keeping the AFRs (Air Fuel Ratios) in each cylinder at a safe level, which in turn, can increase an engines power due to the air being cooler. A bigger bang is then created within the cylinder, providing the correct amount of fuel is added. This can equate to an increase in BHP and torque. The Forge Motorsport intercooler is a perfect performance enhancing product that fits directly to the OEM mounting points, making for a simple install, in a relatively short period of time. No cutting of any components is 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 stealthier 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.    

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Product Description FMINT24 is a performance intercooler for the MQB platforms with the EA888 GEN4 Engine. 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 EA888 GEN4 engine. Our project brief was to develop an intercooler that utilised all of the available space 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. In the MQB chassis the intercooler housing is particularly restricted and confined to a small amount of space, due to it not only housing the intercooler, but also the radiator and air conditioning condenser. The front panel in theory is a sandwich pack that houses the auxiliary cooling components. This means in order to increase the size of the intercooler without paying detriment to the performance of the surrounding items, and with also having very little extra space available, that it can be very difficult to execute the perfect blend of a high flow intercooler within such a close proximity. Our research and development engineers started with a brief to fit our existing intercooler (FMMK7FMIC) that was for the MK7 platform, to our development VW MK8 Golf R. Upon installation, we then tried to establish if we could re-engineer the intercooler with an increased inlet and outlet size along with increasing the volumetric capacity to increase flow along with future proofing the design to work well with highly tuned stage 3 plus EA888 Gen 4 engines. Using a combination of scanning software and traditional measuring methods, the design was created. This was then fine-tuned by our flow dynamics simulations programs (CFD), and the end tanks were initially created by 3D printers. This enabled us to ensure the fit was perfect on the vehicle before any prototype castings or machined billet end tanks were produced ready for dyno testing. Several baffle configurations were designed, and flow simulated to ensure the maximum performance was obtained to keep the core working at its optimum, along with ensuring all its cooling capabilities had been upheld, and that the total volume of the core internal is utilised for optimum performance. With an increase in inlet and outlet sizes, we then turned our attention to the design of our silicone hoses. With flow in mind, we have created a step within the hose so where the hose meets the hot and cold side of the inlet and outlet junctions the transition is seamless, this helps to lesson any disturbance to the airflow and prevent unwanted turbulence. To further aid with flow, the inlet and outlets have been increased to 76mm from the OEM size of 63mm which equates to a 45% increase in surface area. The consideration of space and our clever design has led us to produce several intercooler cores with different fin configurations and internal capacities. Depending on the core design, testing results led us to choose a bar and plate design with over 83% more volume than the OEM intercooler, and with a frontal area increase of 10%. 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, as well as changing the internal fin pitches/shapes and density within the tube; thus enabling us 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. 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 using Performance Remap in Gloucester with their VTEC 4-wheel drive dynamometer. This was to ensure all our data has been achieved with results as accurately as possible by an independent tuner. As you can see from the dyno results below, peak power was increased from stock by 11bhp and 20nm of torque at 5500RPM with the Forge Motorsport performance intercooler installed. The best news is that there are significant torque gains throughout the rev range, meaning that the car power will pick up quicker and pull the whole way through to redline, including an impressive gain in BHP from 5000 RPM TO 6500 RPM. Gains on vehicles with re calibrated software and further hardware performance parts can be expected to be a lot higher due to the substantial drop in IATS when FMINT24 is installed. During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C). We then did a dyno pull from this point which gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.     After more than six pulls on the dyno we still had super safe IAT’s, and the Forge Motorsport intercooler gave results of 34°C at 6548 RPM giving a reduction of 58% over the factory’s intercooler intake temps from 58°C at 6508 RPM. These tests took place in relatively hot conditions with an ambient dyno cell temperature of 23°C proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear. If you use your car for fast road or have a high-performance tune in a hot climate, this product is essential.  Why do we try to decrease IAT's? (Inlet Air Temperature) Temperature and volume of air supplied to your vehicles engine that is compressed by the turbo charger has a better effect on performance when cool as this is to provide the engine with more oxygen (denser air), thus improving the combustion in each cylinder. In addition, by regulating and reducing the air temperature, it also increases the reliability of an engine by keeping the AFRs (Air Fuel Ratios) in each cylinder at a safe level, which in turn, can increase an engines power due to the air being cooler. A bigger bang is then created within the cylinder, providing the correct amount of fuel is added. This can equate to an increase in BHP and torque. ​​​​ 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 is 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 stealthier 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.

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Developed from our direct involvement with BTCC and success with the previous generation I30N, Forge Motorsport is proud to release an oil cooler kit for the Hyundai i30N MK3.5. This oil cooler radiator is lifted straight from our motorsport department, so we know this component performs extremely well, as well as the cores tough and durable construction. Next stage was to design a kit incorporating this core which will fit the i30N Mk3.5 perfectly - the result is a bespoke oil cooler kit with true motorsport development behind it. During our time developing new products for the second generation i30N we found a significant floor with the vehicle especially when tuned. Oil temperatures can climb to dangerous levels when on track or when driven hard in hotter climates, The rising oil temperatures change the viscosity potentially thinning the oil, this will result in only one outcome, a reduction of sufficient lubrication of your engines internal components. Therefore, the FMOC13 is a must have product for the keen driver. The location of the oil cooler at the front of the vehicle’s radiator grill allows for superior air flow. During our development of this product, we have seen oil temperatures reduced significantly. Unlike many oil cooler kits, the FMOC13 keeps the factory oil to water cooler in position. This essentially doubles your engines oil cooling. This new product is not to be confused with a universal oil cooler. FMOC13 has a laser cut aluminium bracket which makes for perfect fitment to the i30N crash bar and has an incorporated side ducting which guides air flow through the core. Manufactured in Gloucester UK, FMOC13 is made to the uppermost standard and is backed up by the Forge Motorsport lifetime warranty. It is available in raw finish or black powder coat finish for the stealthier look. We’ve incorporated a thermostat that is built into the oil cooler sandwich plate, this has been set to open at 85C as this was observed to be the optimal working temperature of the oil cooler when testing, this means the engine is working at its most efficient oil temperature range however hard you push the vehicle.   The kit comes with the following: 1x Forge aluminium sandwich plate1x twin pass oil cooler 4x M6x20 fasteners4x M6 washers2x oil lines 4x M6 Rubber Riv nuts1X M20x1.5 adaptor1X weather stripAll the fixings required 

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Fits Peugeot 308 GTI MK2 Proven to withstand temperatures up to 2500°F or 1370°C Prolongs the life of engine components Improves the appearance of the 308’s engine bay Stainless Steel Rivets and Fasteners Carbon fabric outer shell Calcium Magnesium Silicate Wool constructed Inner Core High temperature Silica fabric   The Forge Motorsport FMTUBL14 is a turbo blanket that has been specifically designed for the Peugeot 308 GTI MK2. This turbo blanket is designed to isolate the radiant heat produced by the turbocharger. The OE heat shield still allows a considerable amount of heat transfer thus creating a warmer engine compartment, which will have an effect on the engines components and increase intake temperatures. This design has been created to withstand the harshest of environments and proven to withstand temperatures up to 2500°F of radiant heat which will assist in protecting and prolonging the life of engine components. Design innovation keeps the heat of the exhaust gases contained within the hot side of the turbocharger, away from the cool side and the intake path which helps reduce turbo lag and air intake temperatures resulting in more power. As a bonus the FMTUBL14 improves the appearance of the 308’s engine bay considerably, The OEM turbo heat shield tarnishes over many heat cycles, a problem which does not affect Forge Motorsport turbo blankets. All Forge Motorsport turbo blankets are designed and manufactured to the highest standards and use superior materials, unlike some turbo blankets which are constructed using substandard materials.

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Highlights: Peak gains of 25bhp Gains of 43nm of torque 113% volume increase Hand fabricated in the UK Kit includes all necessary fittings and instructions included Lifetime warranty This part replaces OEM part number 282702L000 The Hyundai i20N is an impressive hot hatch with plenty of potential for being fun and fast. However, when looking at the OEM intercooler our development team were able to see that this will be a weak point for those owners looking to push more power or enjoy spirited driving and track days. Our development team started with what we learnt from the successful FMINT15 for the Hyundai MK3 i30N, as the 1.6 litre engine in the i20N shares the same design concept as the 2.0 litre in the i30N. We hand fabricated end tanks as a starting point to create a mock-up intercooler, allowing us to understand design parameters. This was then 3D scanned, allowing our 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) was utilised to develop our high flow cast end tanks. This helped us to incorporate a turbo side internal divider to ensure the full volume of the stepped core is utilised for maximum cooling. With the design completed, we 3D printed the end tanks using our Formlabs Form 3L printer, to then test fit to the vehicle to sign off the new design. To complete the development, we had one-off sand-cast end tanks manufactured allowing us to test the design before manufacture was started on the Forge Motorsport performance intercooler. Our industry leading bar and plate core is an increase of 113% in volumetric capacity and an increase of frontal surface area of over 57% than the OEM intercooler/Heat exchanger. FMINT28 is the largest currently available on the market. The inlet and outlet sizes have both been increased in diameter, the hot side from 50mm to 60mm giving a volumetric increase of over 44% from the OEM intercooler, and the cold side from 50mm to 63mm giving a volumetric increase of over 59% from the OEM intercooler. Testing was completed using Performance Remap in Gloucester with their VTEC 4-wheel drive dynamometer. This was to ensure all our data has been achieved with results as accurately as possible by an independent tuner. As you can see from the dyno results below, peak power was increased from stock by 11bhp and 43nm of torque with the Forge Motorsport performance intercooler installed. The best news is that there are significant gains across the entire rev range, meaning that the car will pick up quicker and pull the whole way through to redline, including up to 25bhp increase over stock at 4500rpm. To give consistent result which reflects real-world driving conditions, the dyno pulls were done with the car up to temperature with the radiator fans tripped on. With the OEM cooler two consecutive runs showed a maximum temperature of 44°C at 6747rpm. With FMINT28 installed we ran four consecutive runs, and the temperature didn’t rise to any more than 32°C at 6717rpm. This 12°C is a massive temperatire decrease of 32%. It’s also worth noting that the dyno cells ambient temperature rose from 24°C to 29°C between the test days so you may experience even better results. With this reduced intake air temperature (IAT), you will prevent the stock ECU from pulling out the engines timing which results in a loss of power. If you use a i20N for fast road or have a high-performance tune in a hot climate, this performance intercooler is essential.  This intercooler combined with our intake, and a quality aftermarket cat back exhaust with factory software will deliver you unparalleled levels of performance. The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 2.5 hours depending on competency and tools available. The Forge intercooler weighs 9.65kg compared to the OEM's 3.7kg  

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This performance part replaces OEM part number K1BY-9R504-A This performance inlet pipe for the Ford Fiesta ST MK8 & Puma ST fits between the air filter and turbo inlet pipe and is a highly visible component of the engine bay, accordingly its available in red, blue, grey and black. Its fully compatible with either the OEM filter box or our intake for this application. Unlike the stock Ford hose (K1BY-9R504-A) , the Forge inlet hose maintains a constant internal diameter to ensure a smooth flow of air to the turbo charger, which owners have commented makes the car livelier to drive.  Our high grip hose clamps are included with this product. The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone. This means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist. The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader. Lifetime warranty on Ford performance parts and also makes and models on our website* Complimentary Products The FMINDK38 is the cold air induction system for Ford’s latest generation 1.5-liter 3-cylinder ST engine. Like with all manufacturers in recent times the need to make smaller engines more efficient and more powerful has been an engineer’s top priority, this then creates a problem for the aftermarket manufacturers to improve what is already fitted to the vehicle, nevertheless this hasn’t stopped us at Forge Motorsport. On a tuned vehicle this combination is an essential purchase as the OEM air box is found to be too restrictive to achieve the optimum power figures and smooth power delivery. This beautifully crafted high flow charge pipe is for the Ford Fiesta ST MK8 and Ford Puma ST. This product has been created over many days and months of dyno testing and road testing to prove the products credentials. The boost pipes are a direct replacement to the original hot-side charge pipe which is rather restrictive especially at the turbo end. FMBP6 was developed to remove these restrictions and now features a smooth and enlarged bore size creating a vast improvement in air flow and a reduction in pressure drop.  

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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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The Forge Motorsport FMTUB11 has been designed for the Alfa Romeo MiTo QV. This turbo blanket is designed to isolate the radiant heat produced by the turbocharger. This design has been created to withstand the harshest of environments and proven to withstand temperatures up to 2500°F (1370°C) of radiant heat which will assist in protecting and prolonging the life of engine components.   Design innovation keeps the heat of the exhaust gases contained within the hot side of the turbocharger, away from the cool side and the intake path which helps reduce turbo lag and air intake temperatures resulting in more power.  

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Product Description With modern day aftermarket ECU tuning pushing powerful engines harder. In certain conditions the vehicle will run the risk of receiving inadequately cooled air affecting the engines efficiency and ultimately losing power. With this in mind, Forge are proud to release another PolarCooler as the first auxiliary cooling system for the BMW B58 engine Found in the A90 Supra. Following extensive testing on the road and dyno working with 3 different styles of water core with different fin pitch configurations, we are proud to present the ultimate in frontal water cooling solutions. If you are a keen modifier and wish to push the limits of your A90 this chargecooler is a must, With 177% increase in volume hot climate owners will definitely appreciate the development that has gone into this product resulting in safer IATs (inlet air temps) for a longer period of time meaning when on track it takes longer for the standard ecu to reduce ignition timing which will create power loss. With the Forge PolarCooler it results in more power for longer with peace of mind for track day sessions.  The PolarCooler is available in either a powder coated satin Black finish or motorsport raw Alloy.      The uniquely developed Forge PolarCooler features: An increase of over 170% extra capacity using a 18 fpi (fins per inch) louvre super tech cooling core for maximum cooling. The PolarCooler replaces the OEM chargecooler radiator. This chargecooler has been designed featuring triple pass water flow to ensure all of the surface area of the core is utilised, meaning maximum cooling efficiency. This unique design has allowed inlet temperatures to be lowered by 20°C (68°F) in 3 back to back runs on the dyno. The Forge PolarCooler locates in the OEM position and is supplied with anti-corrosion black powder coat on the hand fabricated end tanks and core or motorsport raw alloy A reduction of the temperature of the cooling water is directly equated with an improved cooling performance of the charged air. With an increase in volume of water introduced to the cooling system the thermal temperatures can be kept at a much reduced level over a longer period, ensuring greater performance and efficiency which in turn is perfect for your fast road and track enthusiast. The Forge radiator has a volume of 23 litres compared to the OEM of just 8.3 litres. Dimensions:OEM:500mm x 615mm x 27mm  (8.3l)Forge Polarcooler:480mm x 600mm x 80mm  (23l) This product is designed, developed and manufactured entirely in Great Britain and is covered by our worldwide lifetime warranty. We estimate that it will take around 4-5 hours to complete installation of this product.

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Forge Motorsport 208 GTi hardpipes replace the turbo to intercooler and intercooler to throttle body plastic pipes on the top of your engine. We also include the silicon hose exiting the turbo which is available in red, blue or black. fits: CitroënDS3(Pre 2016 Only)Peugeot208GTIGTI 2016 Onwards These pipes are more free flowing than stock by removing the resonators and can be fitted to the stock intercooler hoses, or our full front mounting intercooler kit FMINT208GTi. PLEASE NOTE: THIS WILL ONLY FIT THE GTI MODEL AND NOT THE GT WITH 156BHP   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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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). fits: MiniThird generation (F54/F55/F56/F57)F56/F55 Hatchback 2014-F57 Convertible 2016- 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. Our core offers a 31% increase in frontal area over stock (BMW Part no.17517617600) and a correspondingly large increase in volume of 41%. Our end tanks are cast aluminium, made from 3D printed prototypes that we manufactured ourselves in our dedicated R&D facility in Gloucester, UK. The bar and plate design we have used comes after months of testing different core designs and opting for the core with best internal and external airflow. Official supplier to Mini Challenge The Forge F56 JCW intercooler gives a respectable 31% increase in frontal area over stock and a correspondingly large increase in volume of 41% The Forge F56 JCW Intercooler leaves the opposition behind yet again being the first to market The Forge development team have used Solidworks software to improve the OEM end tank design, making the Forge cast version a much freer flowing and efficient unit Testing and flow analysis has made this product a clear market leader Pressure drop under 1 Psi. This product is designed, developed and manufactured entirely in Great Britain and is covered by our lifetime warranty. Click here to find out about information and care for your Forge Motorsport cooling product. *Please note - this product does not fit the 2017 JCW cabriolet*   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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This is a replacement for OEM part number 17517617597 fits: MiniThird generation (F54/F55/F56/F57)F54 Clubman 2015-2019Cooper 1.5 Turbo Petrol (B38)One 1.5 Turbo Petrol (B38)F56/F55 Hatchback 2014-Cooper 1.5 Turbo Petrol (B38)Cooper S 2.0 Turbo Petrol (B48)One 1.5 Turbo Petrol (B38)F57 Convertible 2016-Cooper 1.5 Turbo Petrol (B38) As the preferred and official supplier of to www.minichallenge.co.uk Forge Motorsport is proud to present our for the Mini Cooper 1.5 Turbo F56 Chassis. Our core offers a 123% increase in frontal area over stock (BMW Part no 17517617597). As the originators of the stepped core design way back in 2006, Forge Motorsport is best placed within the market to call on our vast expertise in order to deliver a direct fit that would enhance the performance potential of the BMW Group 1.5 Turbo 3 cylinder engine. Our end tanks are die cast in aluminium for improved internal flow characteristics, developed from 3D printed prototypes that we manufactured in-house at our dedicated R&D facility in Gloucester, UK. The bar and plate core design we have used comes after months of testing different core designs and opting for the core with of internal, external airflow and heat transfer characteristics. Please look through the front grill to ascertain which cooler you need. The FMINT8 has 7 tubes the FMINTMF56 has 11 FMINT8 Or FMINTMF56 Official supplier to www.minichallenge.co.uk The Forge F56 JCW gives a respectable 123% increase in frontal area. CNC machined couplers to ensure a precision fit to the OEM Hose couplers. Supplied with all fitting hardware, no additional purchases necessary This is designed as a direct replacement for the OEM and requires no cutting of bodywork etc. This product is designed, developed and manufactured entirely in Great Britain and is covered by our Worldwide lifetime warranty. Again Forge Motorsport are first to market with a full range of for the Mini (Petrol) F56 Turbo range, 1.5 Turbo Cooper, 2.0 Turbo Cooper s and 2.0Turbo JCW.   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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An alloy header tank for the R58 Model Cooper S. This simply replaces old stock header tank, and reuses the stock water cap from your old header tank.   fits: MiniSecond generation (R55/R56/R57/R58/R59) (2006–2015)R58 CoupeLCI 2012-2015R59 RoadsterCooper S 1.6 Turbo Petrol (N18)JCW 1.6 Turbo Petrol (N18) Hand crafted and polished in the UK making for an easy fitment and replacement. If you are unsure if this product is suitable for your application, please contact us.    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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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. fits: MiniSecond generation (R55/R56/R57/R58/R59) (2006–2015)R55 ClubmanPre LCI 2007-2009 N14/N18 R56 HatchbackLCI 2010-2014Pre LCI 2007-2009 N14R57 ConvertibleLCI 2010-2014R58 CoupeLCI 2012-2015R59 RoadsterCooper S 1.6 Turbo Petrol (N18)JCW 1.6 Turbo Petrol (N18) 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. As a reduction in intake air temperature increases the density of the charge mixture within the combustion cylinder, any temperature reductions will equate to more power. This intercooler is constructed using a combined 80/40mm high thermal efficiency core, with a 250% larger surface area and a 125% thicker base core, to achieve the best possible results. In fact, even in relatively low road speeds/air velocities, our intercooler was able to better the OEM unit by 9°C, with greater improvements being achievable during greater speeds during track testing. The replacement intercooler is supplied with all the mountings to allow ease of installation.   Click here to find out about information and care for yourForge Motorsport cooling product.   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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This Intercooler Resonator delete hose fits the 2007 onwards BMW Mini Cooper S. This hose replaces the two OEM hoses and a sound resonator. The purpose of the OEM resonator is to reduce the roar / whoosh noise that can often be associated with air passing through pipe work. By removing this resonator with a smooth bore hose the resistance is reduced. Several of our competitors claim horsepower gains for the installation of this type of hose, but our own testing showed these to be marginal so we prefer not to make such claims. We did however see change in the torque characteristics with between 10 and 15 ft/lbs improvement on our own test car. It is always difficult to quantify gains for a specific product as a lot will depend on other modifications that have been carried out. fits: MiniSecond generation (R55/R56/R57/R58/R59) (2006–2015)R55 ClubmanPre LCI 2007-2009 N14/N18 R56 HatchbackPre LCI 2007-2009 N14R57 ConvertibleLCI 2010-2014Typically if the car is running tuned software with a free lowing downpipe and exhaust, changes made on the intake, with the fitment of this hose and or a intake filter kit will be more dramatic. From a drivers perspective, after fitting this hose on its own, we did not perceive any increase in noise, but there was a noticeable change in the willingness for the engine to accelerate, which can be associated with the torque improvement and small gain in horsepower.As an added bonus this hose is available in red, blue, or black (a real stealth install) and will withstand greater temperatures and pressures than the original hose.   •    The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone.•    This means the hoses are suitable to be used with  either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.•    The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically•    The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader.•    Lifetime warranty* *T&C’s apply   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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