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Home » Products » Under the Bonnet » Intercoolers

Forge Front Mount Intercooler for Turbo MINI

Reviews	Views	Date of last review
3	10673	8/12/2011

Recommended By	Average Price	Average Rating
100% of reviewers	None indicated	10.0

supersize

Description:	For the 2007 onwards model (R56) BMW Mini Cooper S Turbo we have developed a more efficient intercooler. As a reduction in intake air temperature increases the density of the charge mixture within the combustion cylinder any temperature reductions will equate to more power. This intercooler is constructed using a combined 80/40mm high thermal efficiency core, with a 250% larger surface area and a 125% thicker base core, to achieve the best possible results. See Graph for details of temperature reduction. In fact even in relatively low road speeds / air velocities our intercooler was able to better the OEM unit by nine degrees centigrade, with greater improvements being achievable during greater speeds during track testing. The replacement intercooler is supplied with all the mountings and a replacement lower grill to allow ease of installation. Please note that this kit has been designed to fit behind the original Cooper S front panel. If an alternative aftermarket front panel has been installed, where clearances are reduced, additional trimming may be required.
Keywords:	Forge Front Mount Intercooler
Web site:	http://www.waymotorworks.com/forge-a...r-s-turbo.html

Author

unclemeat
3rd Gear

Registered: February 2008
Posts: 246

Review Date: 10/12/2009

Would you recommend the product? Yes | Price you paid?: None indicated | Rating: 10

Pros:	More horsepower, More turbo efficiency, Future modification
Cons:

For about a month I was taught between a Helix and a Forge intercooler unit... Until I made my monthly visit to WayMotorWorks. Since my last visit WayMotorWorks stocked up on Forge intercoolers and I finally got to see an R56 intercooler in-person. I bought the Forge intocooler knowing what a reputation Forge has not only with the community and review but also the heavy involvment within the aftermarket community. Compaired with other brand units; the welds and manufactored process is unparralleled. This intercooler is a work of art! I was quite blown away by the quality of this intercooler - having worked with aftermarket Greddy and Chineese intercoolers for other modified vehicles. Forge knows what they are doing with this product which is way WayMotorWorks stands behind them - Only the best! Once I saw, I believed, and then - I bought!

The installation was easy enough and required absolutly NO cutting whatsoever. I think the Helix IC requires your front grill to be cut in several places. Not with the Forge! Forge includes a pre-cut front grill which is as bolt-on as they come and in no way visually or structurally impairs the stock appearance. No hassle with placement or fitment necessary. Following installation procedures was easy - included are pictures of each and every bolt or pushpin for getting the bumper cover off and then back on. With taking my time and pictures it took me ~4 hours from start to end, by myself with the car on Jackstands.

The imediate results are the following (on a 2009 Factory JCW)-
1. Lower intake temperatures by up to 50 Degrees F at 19PSI (Stock JCW)
2. Same spool/lag as stock - Dyno shows 100rpm better - Drivability increased
3. More grunt from bottom to top
4. I dyno'd 25whp and 15wtq more than stock above 5,500 RPM - all the way to redline. +5 or so from 3-4,500 rpm.

Future performance / longevity
1. Saves the motor from overworking itself with stock hot intake air temperatures. Too small an intercooler can mean the death to some engines in the long run.
2. Further mod-ability factory allows for increase beyond what the IC provides - More breathing room for improvement.
3. Now I can get my WMW Tune

I also recommend (but not required) getting a Forge Turbo to IC charge pipe also from WayMotorWorks at the same time as purchasing this Intercooler.

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netma1000
2nd Gear

Registered: February 2008
Location: Lake Lanier GA
Posts: 84

Review Date: 5/21/2010

Would you recommend the product? Yes | Price you paid?: None indicated | Rating: 10

Pros:	Demonstrated lower intake temps at highway speeds
Cons:

Also replaced the stock charge and discharge pipe with an NM Charge and Discharge Pipe. Together, I noted an immediate improvement in air intake temperature as stated by unclemeat. The car seems to accelerate a little faster from the line. And, another goal attained was to eliminate the noisemaker noise.

Marine Major
Neutral

Registered: July 2011
Posts: 1

Review Date: 8/12/2011

Would you recommend the product? Yes | Price you paid?: None indicated | Rating: 0

Pros:
Cons:

I too debated between the Forge and Helix intercooler, but when the different route. I purchased the Helix product and just wanted to share with you all that NO cutting was involved. It was a perfect fit and performance results were awesome! BTW, the intercooler was installed on a 2009 JCW Coupe that also included an Alta CAI and catback exhaust.
Semper Fi,
Marine Major

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