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In the development stages, our engineers used their knowledge and sheet metal expertise to help improve vital airflow through the bar and plate core by hand forming alloy sheet metal and the necessary brackets to mount the 83% larger volume intercooler in the OE position. This is the ideal location with a frontal surface area increase of over 27%, and has no detriment to any other of the vehicles cooling components. The development team also created a hand fabricated ducting system that has been skilfully integrated into this superior design, to ensure as much air as possible passes through the face of the intercooler.
The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the intercooler OEM boost tract to give improved flow. The development team also added a custom hard pipe, increasing the diameter 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. If you are looking to enhance this performance package, we would recommend adding our cold side boost pipe FMBP7 to achieve an even more elevated performance experience.
Dyno Testing
With Hyundai using the MK3.5 i30N engine, and them re-developing the turbo charger to run more boost with a larger flow than the previous generation, there is even more reason to replace this restrictive OEM intercooler with the larger Forge Motorsport item.
The development vehicle used for this product already had a stage 1 ECU calibration from Courtney Sport, and was fitted with the Forge Motorsport intake (FMINDK28) and turbo inlet adaptor (FMTIA10). The results below show the vehicles power output before the Forge Motorsport intercooler was installed, using the OEM item the results were still impressive, however after a few pulls the tuned engine did start to struggle keeping the inlet air temperatures low.
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.
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 on the third run, as the inlet air temperature starts to rise, BHP output was measured at 348.3HP with 459 NM of engine torque.
The new addition of the Forge Motorsport intercooler made a huge difference to the vehicles power output and continued to keep the inlet air temps at around 27°C, with gains of 21 BHP and 28 NM of torque at peak, along with a significant increase from 3000 RPM, the performance gains can be felt when driving this vehicle.
After more than six pulls on the dyno, we still had safe IATs, and the Forge Motorsport intercooler gave results of 27°C, nearly 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 20°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 Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 3 hours depending on competency and tools available.
Feature:
- Gains of 21BHP
- Increase of 28NM of torque
- 27% more volume over OEM
- Bar and plate design
- Designed and manufactured in the UK
- Lifetime warranty
- For Instructions CLICK HERE
- Hyundai Kona N
- 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
Make Vehicle | Model | Year |
---|---|---|
2022-2023 Hyundai Kona N |
Kona N | 2022-2023 |
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
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Please note, Pipercross filters are excluded from our Lifetime Warranty
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