Forge Motorsport intercooler for Hyundai Kona N

Key features:

• power increase of approx. 21 bhp
• torque increase of approx. 28 lb-ft
• 27% larger volume than the stock cooler
• bar-and-plate core
• Designed and manufactured in the UK

The Hyundai Kona N differs significantly from the i30N in its crash structure, and testing has shown that the stepped design does not work as well for the Kona N as it does for the i30N. During development, a metal prototype of the cooler was used to optimise airflow. Using hand-formed sheet metal and brackets, an 83% larger intercooler was fitted into the original position. The frontal surface area of the cooler has increased by 27% compared to the original cooler, without affecting the cooling of other vehicle components. The intercooler also includes vanes that direct air onto the active surface of the cooler.

The intercooler inlet and outlet have been increased to 65 mm, representing a 27% increase in cross-sectional area compared to the stock part. The intercooler kit also includes a hard pipe with a diameter increased to 64 mm from the stock 50 mm for maximum cooler performance. The cooler and pipe are supplied with a black textured coating for a subtle look and long service life. For maximum efficiency, we recommend complementing the cooler with a boost pipe on the cold side (code FMBP7).

Using the i30N engine with a different turbocharger setup and higher boost pressure makes the use of a more powerful intercooler even more necessary than with the i30N. The vehicle on which the Forge Motorsport intercooler was tested already had a Stage 1 ECU remap and a Forge Motorsport sports intake (FMINDK28) installed, along with a turbocharger inlet pipe (FMTIA10). After several pulls, the car gradually began to lose power due to high intake air temperatures. On the third attempt, the vehicle registered 348.3 hp and 459 lb-ft of torque.

Installation of the Forge Motorsport intercooler resulted in a significant increase in power, and the intercooler maintained the intake air temperature around 27°C. An increase in power of 21 bhp and torque of 28 lb-ft was measured. Most of the torque increase was measurable from 3000 rpm.

Even after six measurements, the intake air temperature remained at a safe 27°C with the Forge Motorsport intercooler, while the stock intercooler lagged significantly behind at 48°C. Testing was conducted at a relatively low ambient temperature of 20°C. An even greater difference can be expected during hot summer months.

Installation time is approximately 3 hours, depending on experience and equipment. The Forge Motorsport intercooler is a direct replacement for the stock intercooler. The only modification required is to cut off the sensor bracket and then apply anti-corrosion coating.