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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 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
Features:
- 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
- For Instructions CLICK HERE
- Hyundai i20N 2021+
- 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.
⚠ WARNING:
Cancer and Reproductive Harm
https://www.P65Warnings.ca.gov
Forge Motorsport is a world leader in aftermarket car parts, that includes actuators, intercoolers, blow-off valves, fabricated alloy tanks, big brake kits, wastegates, and silicone hoses. The company was founded in 1996 with the simple principles of innovation, crafty designs, and high-quality manufacturing. The company is comprised of passionate petrolheads who are dedicated to designing and developing vehicle-specific performance parts for OEM And turbocharged applications.
If you are looking to get the most out of your Audi, BMW, or Volkswagen’s performance, you can count on Forge Motorsport in the United Kingdom. Each individual Forge branded product proudly states “Made In Great Britain.” Forge Motorsport is based out of Gloucester, England, where its headquarters and manufacturing plants produce its ever-growing lineup of products. The company also has a full sales and distribution facility in Orlando, Florida (Forge USA) and one in Taichung, Taiwan (Forge Asia)
Forge Motorsport’s Manufacturing ProcessAll Forge Motorsport products are manufactured in-house in its state-of-the-art CNC machine shop by a team of highly skilled engineers and fabricators. All Forge production is controlled by the international ISO 9002 standard for manufacturing design and development. Billet parts are machined to the strictest tolerances and undergo exhaustive testing and inspection before they are released. All welding is also done in-house, by Forge’s in-house craftsmen, and boasts unsurpassed quality and robotic-like precision. Not only do Forge Motorsport’s products look great but they also perform second to none. What’s more, all Forge products are guaranteed for life and backed by Forge’s “No Hassle” service promise.
With immense knowledge at its disposal, Forge is honored to supply the leading names and race teams in the world of motorsport, including F1, Rally X, WRC, and Le Mans, as well as several OEM manufacturers.
Forge Motorsport at Vivid RacingVivid Racing carries a wide array of Forge Motorsport parts, including intercoolers, big brake kits, blow-off valves, wheel spacers, wastegates, turbo hoses, intakes, radiators, and much more! If you cannot find a specific item above or have any general questions, please do not hesitate to call our expert sales team at (480) 966-3040. We are here to make the buying experience a simple and pleasant one.
If your Forge product fails or breaks due to a manufacturing issue or defect, we will repair or replace, at no charge to the customer at our discretion. This service will only be carried out IF the Forge product is still in its original unchanged design condition and the item/product has not been modified or changed in anyway. The Forge Motorsport (Limited) Lifetime Warranty will not cover any damage or failure caused by; improper or incorrect installation, normal wear and tear, finished colour/aesthetic appearance of the product, the normal degradation of material over time, or if the product has been exposed to the use of any Traffic Film Remover or alternative acidic cleaner (commonly used in hand car washes).
The warranty will also be invalid if the Forge product has not been fitted to correct applications that it was designed for. Any damage to Forge products that occur outside of the warranty can be sent in for evaluation and a quotation to repair or replace said product along with a return shipping fee. The Forge products that are covered by our (Limited) Lifetime Warranty are to the original purchaser or owner of the Forge item for the lifetime of that said product only. The warranty policy is NOT TRANSFEREABLE However given the quality of the product that Forge manufacture we are confident of great longevity of your “Engineered for Performance†Forge part.
For any warranty claim or query please contact our Forge Motorsport sales team in your region or country. www.forgemotorsport.co.uk UK & EU www.forgemotorsport.com USA and South America www.forgemotorsport.asia Asia
Any shipping or returns to Forge Motorsport must be insured, pre-paid and include a Forge Motorsport Goods Returns Form and a copy of the original invoice or proof of purchase to allow us to better serve you. The terms and conditions to the Forge Motorsport (Limited) Lifetime Warranty policy are subject to change at any time without notice.
Please note, Pipercross filters are excluded from our Lifetime Warranty
