Forge Motorsport Performance Intercooler for MINI F65 / F66 Cooper S & JCW

A high-quality intercooler is the foundation of safe and effective tuning, and the Forge Motorsport Performance Intercooler has been engineered specifically for the Gen 4 MINI F65 and F66 Cooper S and JCW models to deliver the cooling capacity required for modern turbocharged performance.

Replacing the factory intercooler (OEM reference 17519846916), the Forge Motorsport intercooler features a large stepped bar-and-plate core designed to dramatically increase heat transfer efficiency. By reducing intake air temperatures, the intercooler allows denser air to enter the engine, improving combustion efficiency while reducing the risk of detonation under high load. The result is stronger, more consistent power delivery, particularly during sustained acceleration where the standard intercooler can suffer from heat soak.

Extensive development using 3D vehicle scanning and Computational Fluid Dynamics (CFD) allowed Forge Motorsport’s engineers to optimise the intercooler’s internal airflow and end tank design. The result is a highly efficient system that maximises cooling performance without compromising pressure efficiency or throttle response. Despite the significant increase in size and cooling capability, the Forge intercooler maintains 100% plug and play fitment with no vehicle modifications required making installation straight forward.

At the core of the design is a stepped bar and plate intercooler core, chosen for its superior thermal mass and durability compared with traditional tube and fin designs. This construction is ideally suited to the high temperatures and boost pressures experienced in tuned turbocharged engines. The upgraded core provides over 40% greater internal volume and an 82% increase in frontal surface area, significantly increasing cooling capacity while maintaining excellent airflow characteristics and avoiding additional turbo lag.

The intercooler also features high flow cast aluminium end tanks, developed using CFD modelling to ensure optimal charge-air distribution across the entire core. Without proper internal shaping, compressed air tends to travel through the lower section of an intercooler, leaving the upper portion underutilised. Forge’s cast end tank design incorporates internal airflow guides that ensure even distribution across the entire core, maximising cooling efficiency and reducing inlet air temperatures.

Testing has shown temperature reductions of up to 24°C compared to the factory intercooler, particularly above 4,500 RPM where the OEM unit begins to struggle with heat management. Lower intake temperatures support more consistent power delivery, smoother power curves, and greater resistance to heat soak, making this upgrade beneficial for both standard and tuned vehicles.

For modified MINIs, an improved intercooler allows for reduced and more consistent inlet temperatures, this allows tuners to safely run higher boost pressures and more advanced ignition timing, unlocking additional performance while maintaining engine reliability. As such, an upgraded intercooler becomes an essential supporting modification for Stage 2 tuning and beyond.

Every Forge intercooler is hand built at Forge Motorsport’s headquarters in Gloucester, UK, where experienced technicians assemble and inspect each unit to ensure the highest manufacturing standards. A durable anti-corrosion coating with heat-conductive properties further enhances cooling performance and long-term durability. Like all Forge Motorsport cooling products, the FMINT37 is backed by a lifetime warranty.

Key Features

• Temperature reductions of up to 24°C 
• Stepped bar and plate core for superior thermal efficiency
• Over 40% increase in internal volume 82% greater frontal surface area for improved airflow exposure
• High flow cast aluminium end tanks with internal airflow guides
• Smooth, consistent power delivery with no additional turbo lag
• Direct plug and play installation with full instructions included
• Lifetime Forge Motorsport warranty

Technical Specifications

• Weight: 10kg 
• Core Dimensions: 265mm (H) × 620mm (L) × 105mm (W stepped)
• Intercooler Volume: 12.6 litres
• End Tanks: CFD-optimised cast aluminium
• Construction: Bar-and-plate stepped core
• Coating: Anti-corrosion, heat-conductive finish
• Fitment: Direct replacement – 100% plug & play

For enthusiasts looking to build reliable power from the Gen 4 MINI F65 and F66 Cooper S and JCW platform, the Forge Motorsport intercooler provides the cooling performance needed to support both OEM+ upgrades and serious tuning builds.

Fitting instructions are available here

1 x Intercooler 1 x Fitting Guide

Lohen offers professional, in-house fitting for all products at our workshop in Eccleshall, Staffordshire, ST21 6JL. Here are the important things you need to know:

Fitting Cost - £102

Fitting Time - 1 hours

Required Additional Items/Services - N/A

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