PRODUCT DETAILS
This product is ordered directly from Forge Motorsport please allow 2-3 days for delivery
- 37°C reduction in IATs
- Gains of up to 25BHP
- Overall surface area increased by 30%
- Volumetric capacity of 15.7l
- 130% increase in capacity over the OEM
- One of the largest intercoolers on the market today
- Bar and plate core design
- Lifetime Warranty Guarantee
After developing an uprated intercooler for the Audi TTRS 8J, our tuning partners approached us to develop a 2nd version that would be specifically designed for those running 500+ BHP. Even for customers with just a stage 1 tune, gains of around 25 BHP can be expected by just swapping out the relatively small and inefficient OEM intercooler (OE Part No. 8J0145804B).
The standard intercooler fitted by Audi has a volumetric capacity of 6.8l, which essentially bottle-necks the inlet tract to the throttle body, creating a restriction when the boost is increased. We utilised our CAD design to ensure that the end tanks flow in the best way possible, spreading the compressed air evenly throughout, this in-turn lead to superior performance over the stock item. We tested several core configurations during development, with the best all-rounder being our bar and plate design. The overall surface area of the intercooler has increased by 30% providing more cooling capabilities. We utilised all the available space with a volumetric capacity of 15.7l, resulting in an overall 130% increase in capacity over the OEM, making this intercooler one of the largest on the market today.
This intercooler is complimented with our modified OEM crash bar (OE Part No. 8J0807109B), that also doubles as the intercooler support.
Why do we test different cores?
When developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, and a tube and fin style core. Our tube and fin will be tested with different fin pitches and heights, e.g., 22 fins per inch or 17 fins per inch. We will also look at changing the internal fin pitches/shapes and density within the tube, enabling to fine tune the amount of pressure drop the intercooler produces.
Pressure drop is not always a bad thing, as our testing and research has proven on various projects. This is because the pressurized air velocity is being stalled by the pressure drop within the cooler, thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines. As the intercooler reaches its maximum efficiency, the turbo must work a lot harder to force the air through the core. This in-turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is being worked harder.
Having no pressure drop can also prove to be inefficient, as the cooler will not lower the charge temperature again, resulting in higher inlet air temperatures.
Dyno Results
Testing was completed using an independent dyno, we used Powerstation in Tewksbury on their MAHA dyno. This was manufactured by the same people who currently supply BMW M Sport and Mercedes Benz for all their engine calibration and dyno testing.
During testing, we let the car heat soak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 38°C), then did a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge Motorsport intercooler cools much quicker and delivers a greater drop in temperature compared to OEM.
The OEM intercooler produced inlet air temperatures on average of 72°C after 3 pulls, while the Forge Motorsport intercooler reduced the inlet air temperature to 35°C, resulting in a 37°C reduction over the stock item, and being far more superior than our first iteration that has since been discontinued.
The dyno graph shows the comparison between a highly tuned TTRS running our original revision Forge Motorsport intercooler, and after installing the 500+ BHP version. The results repeatedly showed an increase from the 460BHP previously achieved, to 512BHP, creating gains of +52BHP. 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.
Finished in our specially formulated textured black finish, and supported by our lifetime guarantee, this is truly an outstanding performance-enhancing product.
SHIPPING & RETURNS
Delivery
- The normal delivery time for all UK orders is 1-2 days if exporting outside the UK the shipping time is within the checkout process or you can contact our team and we will be happy to assist in advising you a delivery time.
- If the delivery date is to be any longer than this time you will be contacted by one of the sales representatives.
- All orders will be shipped by recognized carriers or The Royal Mail.
- We can only Shop to the Card holders Address, Garage or Work address.
- We are not responsible for any additional costs as a result of extended delivery times, unless prior consent is given in writing by a member A member of the Sales Team.
- Goods are dispatched on the same day, Dependent on stock, If the Goods are out of stock you will be contacted by a member of staff to give you an expected waiting time for the Items ordered.
- For International sales, the products will be sold VAT Free, the courier or customs will contact you for the TAX and duties payment when the product enters your country, if you are unsure or have any questions please contact us.
- Pricing below is for mainland's only unless stated otherwise, whilst we do our best to ensure these prices are correct they are susceptible to change.
Please Note
For orders outside of the UK, The Checkout process will give you a Delivery cost, Please contact us for further information or any delivery Quotations to countries we do not list.
Please email. sales@potn.co.uk and we will get back to you as soon as possible. We will need your full delivery details and what you would like to order to provide a quote.
Country |
Estimated Delivery time |
Cost (GBP) |
Austria |
3 - 5 Working days |
£50.00 |
Bulgaria |
4 - 6 Working days |
£120.00 |
Bosnia & Herzegovina |
4 - 6 Working Days |
£120.00 |
Croatia |
4 - 6 Working Days |
£100.00 |
Czechia |
3 - 4 Working Days |
£60.00 |
Denmark |
3 - 4 Working Days |
£48.00 |
United Kingdom |
1 - 2 Working Days |
£20.00 |
Estonia |
4 - 6 Working days |
£60.00 |
Finland |
4 - 6 Working days |
£60.00 |
France |
2 - 3 Working Days |
£35.00 |
Germany |
3 - 4 Working Days |
£45.00 |
Greece |
4 - 6 Working days |
£60.00 |
Hungary |
4 - 6 Working Days |
£60.00 |
Ireland |
2 - 3 Working Days |
£35.00 |
Italy |
3 - 4 Working Days |
£60.00 |
Latvia |
4 - 6 Working Days |
£60.00 |
Liechtenstein |
4 - 6 Working Days |
£60.00 |
Lithuania |
4 - 6 Working Days |
£60.00 |
Luxembourg |
4 - 6 Working Days |
£35.00 |
Monaco |
2 - 3 Working Days |
£45.00 |
Montenegro |
4 - 6 Working Days |
£120.00 |
Norway |
4 - 6 Working Days |
£120.00 |
Poland |
3 - 4 Working Days |
£60.00 |
Portugal |
3 - 4 Working Days |
£60.00 |
Romania |
4 - 6 Working Days |
£60.00 |
Spain |
3 - 4 Working Days |
£60.00 |
Sweden |
4 - 6 Working Days |
£55.00 |
UK ( Channel Islands) |
2 - 3 Working Days |
£25.00 |
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Delivery
- Items in stock will be despatched the same day if ordering before 2pm
- All orders are shipped on a next working day if mainland UK
- If the delivery date is to be any longer than this time you will be contacted by one of the sales representatives.
- All orders will be shipped by recognized carriers or The Royal Mail.
- We can only Ship to the Card holders Address, Garage or Work address.
- We are not responsible for any additional costs as a result of extended delivery times, unless prior consent is given in writing by a member A member of the Sales Team.
- Goods are dispatched on the same day, Dependent on stock, If the Goods are out of stock you will be contacted by a member of staff to give you an expected waiting time for the Items ordered.
Please Note
- If you are ordering from outside the UK you will not pay VAT on your order, however when the product is shipped you will be contacted by our courier or customs to pay the VAT and any duties upon the products entering the country.
- If you reject the customs payment the product will either be destroyed by customs or returned to us, if the product is destroyed we will be unable to credit you, if the wheels are returned we will deduct the return delivery charge from your credit, this amount will be provided by our courier at the time of the return.
- If you are unsure about any of the above, especially regarding ordering from outside the UK then please get in touch with sales@potn.co.uk or call us on 01604 212140
Returns
We have a 14-day return policy, which means you have 14 days after receiving your item to request a return.
To be eligible for a return, your item must be in the same condition that you received it, unworn or unused and in its original packaging. You’ll also need the receipt or proof of purchase.
To start a return, you can contact us at sales@potn.co.uk. If your return is accepted, we’ll send you a return shipping information, as well as instructions on how and where to send your package. Items sent back to us without first requesting a return will not be accepted.
You can always contact us for any return question at sales@potn.co.uk.
Damages and issues
Please inspect your order upon reception and contact us immediately if the item is defective, damaged or if you receive the wrong item, so that we can evaluate the issue and make it right.
Exceptions / non-returnable items
Certain types of items cannot be returned, like special order goods (such as spare parts or uncommon products), We also do not accept returns for hazardous materials, flammable liquids, or gases such as brake fluid.
Please get in touch if you have questions or concerns about your specific item.
Unfortunately, we cannot accept returns on sale items or gift cards.
Exchanges
The fastest way to ensure you get what you want is to return the item you have, and once the return is accepted, make a separate purchase for the new item. However do advise contacting us first.
Refunds
We will notify you once we’ve received and inspected your return, and let you know if the refund was approved or not. If approved, you’ll be automatically refunded on your original payment method within 10 business days. Please remember it can take some time for your bank or credit card company to process and post the refund too.
If more than 15 business days have passed since we’ve approved your return, please contact us at sales@potn.co.uk.