Forge took one of the very first UK Mini R56’s produced and immediately set to work to improve the OEM intercooler. They did this with the first-ever groundbreaking innovative L Shape intercooler core design.
Many other companies simply copied this design, but Forge still remains the clear market leader due to the exhaustive core testing undertaken in the development stages, we were not content with any air core. The Forge Motorsport development team tested 4 different constructions of air-core before choosing the final stuffed fin stepped design intercooler for the 2007 onwards models (R56/R57) BMW Mini Cooper S Turbo.
 
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.
 
In fact, even in relatively low road speeds/air velocities, our intercooler was able to better the OEM unit by 9°C, with greater improvements being achievable during greater speeds during track testing. The replacement intercooler is supplied with all the mountings to allow ease of installation.