Forge Motorsport Performance Intercooler Kit - BMW Mini F66 Cooper S & JCW

Product Description

• Temperature drops of up to 24°C
• Direct replacement, plug and play fitment
• Greater overall surface area for greater heat dissipation
• High flow cast end tanks ensuring optimum air transition for cooling efficiency
• A smoother power curve
• Volumetric increase of more than 40%, without additional lag
• Frontal area increase of over 82%
• Comprehensive instructions for installation
• Lifetime warranty

Forge Motorsport has a long and proven heritage in the development of high-performance components across every generation of the BMW MINI platform. As the chosen manufacturer for the MINI Challenge race series, we bring unparalleled knowledge, engineering expertise, and real-world motorsport experience to every product we design. This background allows us to consistently deliver some of the most advanced and performance-focused upgrades available for MINI vehicles.

FMINT37 is Forge Motorsports performance intercooler (replacement for OEM part 17519846916) which features an enlarged stepped-core design which dramatically increases heat-transfer efficiency, allowing this cooler to dissipate heat more effectively from compressed intake air. Lower intake air temperatures result in denser air entering the engine, improving combustion efficiency and reducing the likelihood of detonation. The result is stronger, more reliable power delivery, even during sustained high-load usage where stock intercoolers are prone to heat soak.

Design and product evolution

Using a combination of advanced 3D scanning technology and traditional precision measuring methods, Forge Motorsport developed an exact digital model of the vehicle to ensure a perfect fit and optimal performance. This initial design was then extensively refined by our Computational Fluid Dynamics (CFD) engineering team, allowing us to optimise the end tank geometry for maximum airflow efficiency.

The resulting end tank design incorporates a cast alloy construction with internal air guides that ensure the charged air is distributed evenly across the entire intercooler core. Without this critical internal shaping, compressed air naturally follows the path of least resistance, flowing predominantly through the lower section of the core and leaving the upper portion underutilised, leading to elevated intake air temperatures. Forge’s engineered airflow management ensures full core utilisation, delivering significantly improved thermal efficiency and reduced IATs (Inlet air temperature).

The Forge design team has extracted the maximum possible performance gains without requiring any vehicle modification, ensuring FMINT37 remains a true plug-and-play solution. At the heart of the system is a high-performance stepped bar-and-plate intercooler core, delivering over 40% increased internal volume and an 82% increase in frontal surface area compared to the factory unit. The bar-and-plate construction was selected for its exceptional strength and superior thermal mass when compared to traditional tube-and-fin designs, making it ideally suited for high-boost and high-temperature operating environments. The stepped-core layout further enhances airflow distribution and heat dissipation while maintaining excellent pressure efficiency.

Thanks to the substantially increased frontal area, the intercooler benefits from improved airflow exposure, enhancing charge-air cooling both at speed and in stop-and-go traffic conditions. The increased internal volume provides greater thermal capacity, helping maintain consistently low intake air temperatures during repeated acceleration, track use, or aggressive road driving.

Below is a comparison graph illustrating intake air temperatures between the OE MINI intercooler and the Forge Motorsport FMINT37. As shown, the FMINT37 delivers consistently lower intake air temperatures across the entire rev range, highlighting its superior cooling efficiency under real-world operating conditions. Most notably, beyond 4,500 RPM the FMINT37 demonstrates a temperature reduction of up to 24°C compared to the factory intercooler.

Designed for Tuned and Stock Applications
Whether your MINI is completely stock or fitted with performance software, improved intercooling delivers immediate benefits. For modified vehicles, the increased cooling efficiency supports higher boost pressures and more advanced ignition timing, allowing you to safely extract additional performance without compromising engine reliability. This intercooler is essential when upgrading to Stage 2 software.

Hand crafted in the UK to the highest quality

Technical details

• Weight: 10KG
• Core Dimensions: H 265mm, L 620mm, W 105mm (stepped)
• End box material: Cast aluminium (CAD-optimised)
• Coating: Anti-corrosion coating with heat-conducting properties
• Intercooler volume: 12.6 Liters
• Fit:100% Plug & Play