The Pro Alloy Intercooler is not like any other on the market at the moment. They have replaced the near side cast horn of the OEM cooler with our own elbow and machined flanges. This now allows us to squeeze in a much larger intercooler core. The difference from standard this has given is clear to see in the stats below.
 
STANDARD INTERCOOLER CORE SPEC – 275mm x 160mm x 50mm
 Core Surface area = 275mm x 160mm = 440 Sq/cm
 Core Tube Size  = 8mm x 50mm
 Core Tube Count = 11 off Live Tubes
  
PRO ALLOY INTERCOOLER CORE SPEC – 390mm x 275mm x 50mm
 Core Surface area =390mm x 245mm = 955.5 Sq/cm
Core Tube Size = 8mm x 50mm
Core Tube Count = 13 off Live Tubes
 
SUMMARY OF STANDARD VS PRO ALLOY INTERCOOLER
126.3% Increase in core surface area
18.2% Increase in core flow area
  
These stats give you a good indication of how much of an increase in cooling, flow and performance this new kit will provide. Next was to make better use of the air entering the bay via the Cooper S’s well-recognised bonnet scoop. When you shut the bonnet the foam on the underside of the bonnet will form a tight seal with the intercooler’s scoop making sure all the fresh air is forced straight through the intercooler. These trick features come with no big adjustments to the car, there’s no cutting or drilling to be done, just simply unbolting OEM parts and bolt the new unit in.
As with all of our products we build to the highest quality, all of our intercoolers are pressure tested to ensure they’re ready to handle the boost pressures expected.
The kit comes with all necessary parts to fit the unit and is available in Satin Black - With or without PRO logo on core face.
 
Note from pro alloy: "We have noted that on some installations there is a possibility of a boost leak from the mating surface of the throttle body flange under high boost applications. The gasket used at this joint is only suitable for use once and must be replaced every time this joint is disturbed. We also highly recommend that a suitable flexible gasket sealant is used on either side of the gasket to further ensure a complete seal against leaks. We now stock the OE gaskets which are available to order with your intercooler kit."