Description

Forge Performance have designed, produced and tested this product at their UK Headquarters to get it perfect before release. 

Throughout the development process FP have strived to improve the efficiency and performance of the Yaris GR’s engine. Their project brief was to develop an intercooler utilising all of the available space available in the original position of the OEM intercooler, and to ensure the inlet air temperature is reduced, without any negative effects on the boost pressure or engine and transmission cooling.

Using a combination of scanning software and traditional measuring methods, and then fine tuned by Forge’s computational fluid dynamics (CFD) team, allowing the end tanks were initially created by 3D printers. Then allowing alloy cast prototypes from the 3D prints using a sand casting technique and started the testing procedure on various types of intercooler cores.

Before getting to work on the dyno, we spec’d three different type of cores; one of these being bar and plate and two being a tube and fin construction – with all three cores having different internal and external fin pitches and configurations. We then welded the test parts ready for testing along with fabricating an internal baffle to the inlet (hot side) of the end tank. This is to ensure, from our CFD research, that the total volume of the core internal is utilised for optimum performance.

Features:

• Minimum Gains of 10bhp and 10lbft
• Temperature drops of up to 20°C over factory
• Reduced turbo lag, means increased response
• Greater intercooler core surface area for greater heat dissipation
• Made with a race spec’d tube and fin construction air core
• High flow sand cast end tanks welded to the core ensuring optimum air transition for cooling efficiency
• Dyno proven horsepower and torque gains, see data sheet
• A smoother power curve, for transitional torque
• Volumetric increase of more than 100%, without additional lag, and factory position fitting
• Includes all necessary hardware and instructions for installation