Toyota Corolla GR Front Mount Intercooler - Forge Motorsports

Toyota Corolla GR Front Mount Intercooler - Forge Motorsports
 
Product Code: FMINT34 
 
Product Description:
Gains of 10bhp and 10lbft
Temperature drops of up to 20C
Reduced turbo lag, increased response
Greater overall surface area for greater heat dissipation
Utilising a race specification Tube and fin construction air core
High flow cast end tanks ensuring optimum air transition for cooling efficiency
Dyno proven horsepower and torque gains
A smoother power curve
Volumetric increase of more than 100%
Frontal area increase of over 40%
Includes necessary hardware and instructions for installation
Lifetime warranty
 
Following on from our successful launch and testing of our intercooler designed for the Yaris GR our customers reached out to us for a cooling solution for the Corolla GR. FMINT34 is a performance intercooler for the Toyota Corolla GR. This part replaces OEM part number JD127000-1451.
The Corolla GR is currently not available for the UK market so we worked closely with our USA branch to bring a solution to market that has been designed at our headquarters in Gloucester UK. Throughout the development process we have strived to improve the efficiency and performance of the Corolla GR’s engine; our project brief was to develop an intercooler utilizing all 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.
 
In order to fit the designed intercooler to the Corolla GR's platform we designed spacers to fit behind the Corolla GRs OEM crash bar, this results in no cutting of the vehicle and ensures the modification is 100% reversible along with helping to fit the deepest performance core behind the GRs OEM bumper. The spacers are manufactured from 6082 aerospace billet alloy and anodized for surface protection and longevity. The first iteration fitted the vehicle perfectly, however our technicians and engineers felt the inlet and outlet should be enlarged along with providing the end user with the necessary boost pipes to ensure flow was maximized on the Toyota`s GR 3 cylinder engine.
Before getting to work on the DYNO we specked three different types 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 utilized for optimum performance.
 
Final core to test had a slightly smaller thickness than the two previous variants resulting in a slightly smaller volume, and with the hottest test day so far, of all the intercoolers in question at 25.4°C within the dyno cell we were not confident we could improve on the previous results. The results however speak for themselves. On the third pull inlet air temps stayed at a steady 40°C and with the highest BHP gain at 307.3 BHP, and torque peaking at 296.4 lbs/ft. We had found our winning formula. At this point though we do not simply stop, we repeated our testing to ensure our results were true and checked all our test vehicles sensor data to ensure there were no negative effects.
As the hot and cold side, inlet and outlet, have been increased to 60mm, we have included within the intercooler kit all the necessary silicone hoses and hardware to complete the installation, and connect to the OEM parts. Compared to the OEM intercooler, the improved Forge Motorsport product has a surface area increase of over 42% and an internal volume increase of over 100%. Gains of more than 10bhp and 10 lbs/ft. These gains can be even higher depending on your vehicles state of tune and complementing performance products like Forge Motorsport’s FMTIA8 and FMINDK43, with the inlet duct FMINLD1.
The Forge Motorsport intercooler is a perfect performance enhancing product that fits directly to the OEM mounting points, making for an easy install, in a relatively short period of time. No cutting of any components are needed, making the installation reversible if the vehicle needs to be returned to stock at any time in the future. The core and end tanks are finished in our black textured anti corrosion coating that also aids with its thermal properties and keeps the product looking that bit more stealthy or OEM+. The Forge Motorsport lifetime warranty on all hardware products shows the trust we have in the quality of our products while they are being enjoyed on your pride and joy.