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Description
Product Description
Highlights:
- Gains of 21BHP
- Increase of 28NM of torque
- 27% more volume over OEM
- Bar and plate design
- Designed and manufactured in the UK
- Lifetime warranty
Following the success of our performance enhancing products for the Hyundai MK3 i30N and Veloster N, it was only obvious we should further develop on another of Hyundai’s popular performance N platforms, the Hyundai Kona N. Due to the difference in crash bar design, and following intensive testing, we found that, unlike the i30N, a stepped core was not the best performing intercooler during testing, neither would it offer to be a completely reversible plug and play solution.
In the development stages, our engineers used their knowledge and sheet metal expertise to help improve vital airflow through the bar and plate core by hand forming alloy sheet metal and the necessary brackets to mount the 83% larger volume intercooler in the OE position. This is the ideal location with a frontal surface area increase of over 27%, and has no detriment to any other of the vehicles cooling components. The development team also created a hand fabricated ducting system that has been skilfully integrated into this superior design, to ensure as much air as possible passes through the face of the intercooler.
The inlet and outlet sizes have been increased in diameter to 65mm, giving an increase of 27% more volume over the intercooler OEM boost tract to give improved flow. The development team also added a custom hard pipe, increasing the diameter to 64mm, up from the factory 50mm. This replaces the stock factory pipe on the hot side to ensure this package gives you all you need for maximum performance gains on high levels of tune.
The boost pipe and intercooler come in our standard black textured finish powder coat for maximum longevity. If you are looking to enhance this performance package, we would recommend adding our cold side boost pipe FMBP7 to achieve an even more elevated performance experience.
Dyno Testing
With Hyundai using the MK3.5 i30N engine, and them re-developing the turbo charger to run more boost with a larger flow than the previous generation, there is even more reason to replace this restrictive OEM intercooler with the larger Forge Motorsport item.
The development vehicle used for this product already had a stage 1 ECU calibration from Courtney Sport, and was fitted with the Forge Motorsport intake (FMINDK28) and turbo inlet adaptor (FMTIA10). The results below show the vehicles power output before the Forge Motorsport intercooler was installed, using the OEM item the results were still impressive, however after a few pulls the tuned engine did start to struggle keeping the inlet air temperatures low.
During our extensive testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of around 40°C), we then did a dyno pull from this point. In doing this, it gives a more consistent result and reflects real-world driving conditions more accurately.
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. As you can see on the third run, as the inlet air temperature starts to rise, BHP output was measured at 348.3HP with 459 NM of engine torque.
The new addition of the Forge Motorsport intercooler made a huge difference to the vehicles power output and continued to keep the inlet air temps at around 27°C, with gains of 21 BHP and 28 NM of torque at peak, along with a significant increase from 3000 RPM, the performance gains can be felt when driving this vehicle.
After more than six pulls on the dyno, we still had safe IATs, and the Forge Motorsport intercooler gave results of 27°C, nearly halving the factory’s intercooler intake temps from 48°C. These tests took place in relatively cold conditions, with an ambient dyno cell temperature of 20°C, proving how inefficient the stock intercooler is. In the summer months, the stock intercooler along with higher inlet air temperatures will have a hugely negative impact on the engine’s performance. In these conditions, the engine management will retard the ignition, resulting in a lower powered engine as temperatures rise and the ECU then pulls out the timing to stop detonation. On a mapped vehicle, the results will be even more detrimental and can lead to possible premature engine wear.
This intercooler combined with our intake, and a quality aftermarket cat back exhaust with factory software will deliver you unparalleled levels of performance.
The Forge Motorsport front mount intercooler has all the necessary hardware to install the kit in approximately 3 hours depending on competency and tools available.
Complimentary Products
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Forge Motorsport cooling product.
Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.
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Compatible Vehicles
Instructions
Hyundai Kona N Performance Intercooler Upgrade
Warranty
Warranty Information
The majority of Forge Motorsport products come with a limited lifetime warranty. All warranty claims must be accompanied by the original proof of purchase to enable us to help you — failure to supply this proof will result in your claim or enquiry being denied. Please note that some products are excluded from the Forge lifetime warranty and instead carry their own specific warranty terms — for example, air filters, electrical components, coil packs, carbon fibre products, and suspension kits. This page is a summary only; a full and current list of exclusions, along with their specific warranty terms, can be found on our Terms & Conditions page.
For further information, please call our customer service team on +1 865 951 7456 or email sales@forgemotorsport.com
Do not use aggressive (acidic) car cleaning products, particularly traffic film remover solutions or shampoos, to clean your intercooler, radiator, or oil cooler. The use of these products can damage Forge Motorsport cooling systems and invalidate your warranty. These are often found at car washes. A light, warm, soapy solution (free of harsh acidic cleaning compounds) should be used to clean your cooler, and thoroughly rinsed away afterwards. We recommend that you inspect your product regularly for bent and/or crushed fins — any bent fins should be carefully straightened to allow ambient air to pass through the core face. At the time of installing your Forge radiator, an approved coolant must be used. Be sure you never mix coolant types, and always use distilled water.
This warranty does not apply to any defect in the goods arising from fair wear and tear, wilful damage, accident, negligence by you or any third party, use otherwise than as recommended by the supplier, failure to follow the supplier's instructions, or any alteration or repair carried out without the supplier's approval.
This does not affect your statutory rights.
Ignition Coil Packs
Forge ignition coil packs carry a 12 month warranty against manufacturing defects (not our Lifetime Warranty), from date of purchase. As coil packs are often swapped as a full set on suspicion rather than a confirmed fault, claims must identify the specific faulty unit(s) with supporting evidence (e.g. a diagnostic misfire code) and proof of purchase. Full sets cannot be claimed without this. See full terms and conditions for details.
Electrical Components
Electrical components supplied with Forge Motorsport kits — including solenoids, wiring harnesses and looms — are covered by a 12 month warranty against manufacturing defects, rather than our standard Lifetime Warranty. This covers faulty materials or workmanship only, and does not cover damage from incorrect installation, water ingress, wear, incorrect wiring, or faults originating from your vehicle's own electrical system or other aftermarket electrical accessories. Full terms, including how to make a claim, are available in our Terms & Conditions.
Heat Management Products (Turbo Blankets and Gold Reflective Heat Barrier)
Turbo blankets and our gold reflective heat barrier are covered by a 6 month warranty against manufacturing defects (not our Lifetime Warranty), from date of purchase. Turbo blankets cure and lose flexibility over their first few heat cycles as a normal part of fitting. Once heat-cycled they should not be removed. The gold reflective heat barrier is designed for components such as engine covers, intake pipes and induction trays, not for direct contact with exhausts or turbine housings. See Terms & Conditions for details.
Shipping
Shipping
USA Deliveries
All Deliveries are sent via Fedex. We cannot guarantee delivery timelines as all orders are up to shipper schedules and routes. Delivery fee is a Flat Rate of $20 fo all orders over $20. Orders below that value are costed out based on weight. Signature required may be added to your package. Orders can not be re-directed, held, or re-scheduled.
Shipping outside of the Lower 48- Duty Charge Information
All Forge products are sold with a Delivery Duty Unpaid (DDU) status and an import tariff may apply to your order. Customers will be contacted by the Customs and Excise authority in the destination country regarding payment prior to delivery, and it is important that correct contact telephone number and email information be submitted with the order to facilitate this part of the delivery process.
Our shipping methods ensure safe and timely delivery of your new Forge products. For further information on cost and delivery times, please contact Forge using the info@forgemotorsport.com email address if you require any more information. We reserve the right to change the delivery service and company at any time.
***Once a product has left our warehouse and is in the possession of the shipping company, any claims must be made directly with that shipper however we can assist with most cases.
