Forge Motorsport intercooler for Hyundai Veloster II (JS) N facelift

Forge intercooler for the Hyundai Veloster N facelift, including versions with DCT transmission.

If you use your Veloster N for fast road driving or have a high-performance software upgrade installed in a hot climate, this product is essential.

Based on a proven bar-and-plate core design and using SolidWorks 3D modelling and CFD (Computational Fluid Dynamics) flow simulations, we developed high-flow cast end tanks. The turbine-side end tanks feature an internal divider that ensures the entire volume of the stepped core is utilised. The bar-and-plate core volume is more than 129% larger, while the frontal area is more than 71% larger than the original intercooler, making the Forge intercooler one of the largest currently available for this model. For optimal cooling efficiency, the development team also created special air ducting, carefully integrated into the product design and ensuring it follows the inner contour of the Veloster N’s front bumper.

The diameter of the inlet and outlet connections has been increased to 65 mm, providing 27% greater volume than the original intercooler and improved flow. The development team also added a special rigid pipe with its diameter increased by 14 mm—from the standard 50 mm to 64 mm. This pipe replaces the original hot-side pipe and provides everything needed for optimal operation at higher software upgrade stages. The boost pipe and intercooler are protected with a standard black textured powder coating for the longest possible service life.

During the development of the Veloster N intercooler, we tested various core designs before selecting a high-quality bar-and-plate design, also used in our highly successful intercoolers for the Audi RS3 and TTRS 8S. The result is minimal pressure drop.

The results were excellent: intake air temperatures (IAT) were reduced by half, while vehicles with a software upgrade achieved significant gains.

During extensive testing, we left the vehicle on the dynamometer until the radiator fans switched on and off, with the intake air temperature at approximately 40 °C. We then carried out a dynamometer run. This procedure provides a more comparable result and more accurately replicates everyday driving conditions. The Forge intercooler cooled significantly faster and achieved a greater temperature reduction than the original intercooler.

After more than six dynamometer runs, intake air temperatures still remained at a very safe level. The Forge intercooler reached 24 °C, reducing the intake air temperature by half compared with the original intercooler, which reached 48 °C. The measurements were carried out in relatively cool conditions, with the dynamometer cell temperature at 15 °C, highlighting the inefficiency of the original intercooler. During the summer months, higher intake air temperatures combined with the original intercooler will have a strongly negative effect on engine performance. In such conditions, the ECU will reduce ignition advance to prevent detonation, resulting in lower engine power. In a vehicle with modified software, the consequences may be even more pronounced and could lead to premature engine wear.

The Forge Motorsport front-mount intercooler includes all the necessary fitting hardware. Installation takes approximately 2.5 hours, depending on the installer’s experience and the tools available.

Suitable for: Hyundai Veloster II (JS).

Compatible vehicles (manufacturer data)

Before ordering, check that the product matches your vehicle (model, year and engine). If in doubt, write to us — we will check for you.