Forge Motorsport intercooler for Hyundai i20N

Main features:

• power increase of up to 25 bhp
• torque increase of up to 43 Nm
• core volume increase of 113%
• hand made in Great Britain
• mounting hardware included

The Forge Motorsport development team based the i20N intercooler development on the very successful intercooler for the i30N model, as the 1.6 turbo and 2.0 turbo engines used from the i30N are also very similar in design. The intercooler flanges were hand-made so that they could be scanned using a 3D scanner and fine-tuned using advanced CAD (Computational Fluid Dynamics) software for the most perfect airflow into and out of the intercooler core.

Thanks to the use of CFD software, it was also possible to design an airflow divider on the turbocharger side, which ensures that the entire volume of the stepped intercooler core is used. The flanges were printed using a Formlabs Form 3L 3D printer for testing after a thorough design. The final product then uses cast flanges.

The core itself is a bar-and-plate design, and its volume is 113% larger than the factory intercooler, with a 57% increase in frontal area. It is currently the largest intercooler for the i20N in the world. The inlet and outlet have also increased in size compared to the factory version. The hot side inlet has increased from 50 to 60 mm with a 44% increase in volume, and the cold side outlet has increased from 50 to 63 mm, representing a volume increase of 59%.

Power measurements were taken at Performance Remap in Gloucester. Peak power increased by 11 bhp and torque increased by 43 Nm. However, the increase is evident not only at the peak but throughout the entire rev range. The maximum power increase was then measured at 25 bhp at 4500 rpm.

To ensure the results were as close as possible to real-world driving conditions, temperature measurements were taken once the engine had warmed up to operating temperature and the fan was running. The thermometer showed a temperature of 44°C at 6747 rpm after two temperature measurements on the original intercooler. After the same measurement on the car after installing the FMINT28 intercooler, the temperature did not exceed 32°C at 6717 rpm. This 12°C difference represents a decrease of 32%!

This decrease in intake air temperature means that the car's ECU will not have to change the ignition timing and artificially reduce engine power. If you run your i20N on the track or for fast rides on back roads in higher summer temperatures, replacing the intercooler should be a matter of course for you.

The Forge Motorsport intercooler comes with all the necessary installation hardware and should take approximately 2.5 hours to install, depending on the experience and equipment of the installation shop.

The weight of the Forge Motorsport all-aluminium intercooler is 9.65 kg compared to the weight of 3.7 kg for the factory part.