- 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
Following the success of our performance enhancing products for the Hyundai MK3 i30N and Veloster N, it was only obvious we should further develop on another of Hyundai’s popular performance N platforms, the Hyundai Kona N. Due to the difference in crash bar design, and following intensive testing, we found that, unlike the i30N, a stepped core was not the best performing intercooler during testing, neither would it offer to be a completely reversible plug and play solution.
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.
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.
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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.
The majority of Forge Motorsport products come with a limited lifetime warranty (brakes pads excluded). All warranty claims must be accompanied by the original proof of purchase to enable us to help you. Failure to supply this proof will result in your claim or enquiry being denied.
For further information, please call our customer service team on +44(0)1452 380999 or email email@example.com.
Do not use aggressive (acidic) car cleaning products, particularly traffic film remover solutions or shampoos to clean your intercooler, radiator, or oil cooler. The use of these products can damage Forge Motorsport cooling systems and invalidate your warranty. These are often found at car washes. A light, warm, soapy solution (free of harsh acidic cleaning compounds) should be used to clean you cooler and thoroughly rinsed away. We recommend that you should inspect your product on a regular basis for bent and/or crushed fins. Any bent fins should be carefully straightened to allow ambient air to pass through the core face. At the time of installing your Forge radiator, an approved coolant must be used and added to the coolant system. Be sure you never mix coolant and always use distilled water.
This warranty does not apply to any defect in the goods arising from fair wear and tear, wilful damage, accident, negligence by you or any third party, use otherwise than as recommended by the supplier, failure to follow the supplier’s instructions, or any alteration or repair carried out without the supplier’s approval.
Next day delivery applies to orders processed before 12 noon Monday to Friday, subject to stock availability and geographical restrictions. 'Next day' refers to next working day. We cannot guarantee next day delivery for orders placed after this time. Whilst we endeavour to honour our next day service, next day delivery cannot be guaranteed due to other extenuating circumstances. Full details
Delivery is free of charge for all orders £100 (ex VAT) or over. Products are sent by standard DPD service which is usually a next day service, but can take 2 days in transit. We reserve the right to ship smaller, lower value items via Royal Mail or any other service. (Not including Scottish Highlands, Scottish Isles, Northern Ireland, Guernsey, Jersey, and Isle of Man where charges will vary).
Europe and Worldwide
Delivery service charges will vary depending on the quantity of product ordered, the related parcel size, and destination postcode. Live shipping rates will be calculated at checkout using ShippyPro and dependent on criteria, you will be given the option of DHL, DPD, or FedEx courier services.
Shipping into the EU - Duty Charge Information
All Forge products are sold with a Delivery Duty Unpaid (DDU) status and an import tariff may apply to your order. Customers will be contacted by the Customs and Excise authority in the destination country regarding payment prior to delivery, and it is important that correct contact telephone number and email information be submitted with the order to facilitate this part of the delivery process. Some couriers are charging an admin fee for shipping into the EU.
If we detect at checkout that you are located within the European Union (EU), you are eligible for a contribution towards your import duty and tax payments. We can add an additional 20% on the total cost of your order, we will then pay the duty and tax costs above your contribution. This offer will ensure the price you pay at checkout is the total you pay, with no additional charges. It will also ensure you have the fastest possible delivery, with no delays. For more information, please see here
Our shipping methods ensure safe and timely delivery of your new Forge products. For further information on cost and delivery times, please contact Forge using the firstname.lastname@example.org email address if you require any more information. We reserve the right to change the delivery service and company at any time.
Forge Motorsport ships via either UPS, FedEx, DHL (primarily for outside of UK), DPD (primarily for UK), or any other courier we chose. Other shipping options may be available for an additional fee over and above the actual shipping costs. Once a product has left our warehouse and is in the possession of the shipping company, any claims must be made directly with that shipper however we can assist with most cases.