Intercooler for Hyundai i20N

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. 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 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.