We started with improving airflow through the intercoolers with the use of enlarged 60mm silicone hoses, and a redesign of the intercooler end tanks. Then with the charge air sorted, we looked at the cooling air that passes over the intercooler. Our testing showed that the original OEM ducting performed brilliantly so satisfied that it was up to the specification needed we thought we should aim to make a true directly replacement kit, by designing the intercoolers to install perfectly with all the OEM mountings. The new ‘coolers are similar in dimension to the OEM units, but are measurably thicker. The real improvement came with a complete re-design of the intercooler core after our preliminary tests proved a bar and plate design to be more thermally efficient in this installation.

In tests the Forge unit managed a creditable drop in intake temperature of some 24° centigrade, which allows the engine to produce more power and torque throughout the rev range , and of course with the engine running cooler, engine longevity should also be improved.

As supplied by Regal Autosport, this was an already tuned car, with tiptronic transmission, so on completion we promptly handed it over for their impartial assessment of our craftsmanship. The below Dyno graph shows the runs before and after the intercooler modifications. The solid lines relating to the stock intercoolers, the dotted lines are with the Forge kit, with no change to the ECU whatsoever.

Note: Our kit is supplied with all components required and comprehensive instructions.