Hyundai i30N Sedan Forge Motorsport Intercooler

A new Forge intercooler upgrade for the Hyundai i30N Sedan is available. Forge developed a high-flow hand formed end tanks designed to optimize performance while making the most of the space available in the i320n sedan chassis, enhancing both airflow and cooling capacity.

The bar and plate core delivers an impressive 111% increase in volume and a 58% boost in frontal surface area compared to the stock cooler, making the Forge intercooler one of the largest and most effective upgrades currently available for the Elantra N. To further enhance the Forge Motorsport intercoolers cooling efficiency, our team engineered a custom-fabricated ducting system that integrates seamlessly with the vehicle’s front bumper. This ensures perfect fitment and directs airflow precisely where it’s needed most.

he inlet and outlet sizes have been increased to 65mm, providing 27% more volume than the factory unit to optimize airflow. Additionally, we designed custom Silicone hoses to give the enthusiast a package that has seamless integration to the vehicles surrounding engine components. This complete package ensures maximum performance gains for vehicles at any tuning level. The intercooler is finished with our signature black textured powder coating, offering exceptional durability and longevity.

Extensive testing of multiple core designs led us to select a high-quality bar and plate configuration, the same trusted design featured in our highly successful Audi RS3 and TTRS 8S intercoolers. The internal core design, fin shape and amount minimizes pressure drop while maximizing cooling efficiency, ensuring consistent performance gains under demanding conditions.

Forge  results speak for themselves. Inlet air temperatures (IATs) were reduced by half, unlocking significant performance improvements for tuned vehicles. During testing, we simulated real-world conditions by allowing the vehicle to heat soak on the dyno, with the radiator fans cycling on and off at an inlet temperature of approximately 40°C. From this baseline, dyno pulls demonstrated the Forge intercooler’s ability to deliver a much greater drop in temperature compared to the stock cooler.