Focus RS MK3 Intercooler

Even though we were one of the lucky few to get our hands on one of the first RS MK3's in the country, we decided to take our time with our new line of products and make them right. When fitting upgraded parts to a car hot off the production line, you'll be after the very best in quality, which is why (as always) we've designed our parts to fit to the same precision as the OEM part. No chopping or grinding to your car, a straight bolt on fitment, with comprehensive step by step fitting instructions included to make the job simple.

The new all aluminium Intercooler features a large air scoop surrounding the core face to grab all the incoming air from the RS's front bumper, ramming it through the lightweight alloy core. The end tanks are designed for maximum flow and strength and are shaped to guide the air through the core with as little resistance as possible. Each end tank is individually hand crafted by our team of engineers, with precision TIG welding on the inside and outside of the tanks. This helps to improve charge air flow through the internal surfaces, as well as making them ultra strong - a massive improvement over the weak, OE crimped on, plastic part.

Dimension differences

The overall size of the unit has grown drastically, the stats below show how much more core we've managed to fit behind the front bumper.

Standard Intercooler vs. Pro Alloy Intercooler key details:

Standard Intercooler Core Details:

• 1 off Intercooler @ 615 x 195mm

• Single Row Core

• 11 Live Tubes

• External Tube size                = 80mm x 10mm

• Internal Tube Size                = 79.6mm x 9.6mm 

  Pro Alloy Intercooler Core Details:

• 1 off Intercooler @ 680 x 220mm

• Twin Row Core

• 28 Live Tubes

• External Tube size                = 50mm x 8mm

• Internal Tube Size                = 49.2mm x 7.2mm

  Calculated External Surface Area & Internal Flow Comparison:

• 24.9% Increase in external core surface area when the Pro Alloy Intercooler is compared to the standard Intercooler.

• 23.8% Increase in internal flow area when the Pro Alloy Intercooler is compared to the standard Intercooler.

Results from testing

For months we gathered data to see how our new creation stacks up against the OEM unit. Controlled test on the Dyno as well on the road data logging. With a larger, more efficient core and efficient end tank design the results are impressive. As well as our own testing we supplied a prototype kit to a well known Focus tuning specialist to enable them to compare our new kit to some of the other well known brands. The Dyno graph shows how the new kit stacks up against the competition. 

The dyno graph shows a 30% improvement in cooling efficiency when compared to the OEM intercooler and a 10% improvement when compared to the other aftermarket intercoolers.

The 'fit and forget' bolt on fitting also makes the installation easily reversible if you want to return back to standard. All our intercoolers are pressure tested to ensure they can handle the required boost pressures they're up against once installed. As with all our products, this is covered by our warranty policy to back up our confidence in our products.

Available in satin silver or satin black, with or without core face logo.