Description
Pro Alloy Ford Focus Mk3 RS Intercooler
Long awaited release of our 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 brand new car, a straight bolt on fitment, with comprehensive step by step fitting instructions included to make the job simple for the less experienced enthusiasts.
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 tube and fin 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 craftsmen, with precision TIG welding on the inside and outside of the tanks, helping 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 slip in behind the front bumper.
Standard Intercooler vs. Pro Alloy Intercooler key details:
Standard Intercooler Core Details:
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1 off Intercooler @ 615 x 195mm
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Single Row Core
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11 Live Tubes
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External Tube size                = 80mm x 10mm
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Internal Tube Size                = 79.6mm x 9.6mm
Pro Alloy Intercooler Core Details:
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1 off Intercooler @ 680 x 220mm
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Twin Row Core
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28 Live Tubes
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External Tube size                = 50mm x 8mm
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Internal Tube Size                = 49.2mm x 7.2mm
Calculated External Surface Area & Internal Flow Comparison:
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24.9% Increase in external core surface area when the Pro Alloy Intercooler is compared to the standard Intercooler.
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23.8% Increase in internal flow area when the Pro Alloy Intercooler is compared to the standard Intercooler.
Results from testing
Over the last few months we’ve been gathering 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. In parallel with our own testing we have also supplied a prototype kit to a well known Focus tuning specialist, to enable them to carry out some independent and impartial testing, comparing our new kit to some of the other well known brands. The graph below shows how the new kit stacks up against the competition.
The above graph shows a 30% improvement in cooling efficiency when Pro Alloy kit is compared to the OEM intercooler and a 10% improvement when compared to the closest of the other aftermarket intercoolers tested.
The ‘fit and forget’ bolt on type of fitting also makes the installation easily reversible if the time comes you want to return back to standard. All our intercoolers are pressure tested underwater to insure they can handle the required boost pressures they up against once installed.  As with all our products, this is covered by our warranty policy to back up our confidence in our products. Again, as with all our products it is available with a choice of finishes – satin black or satin silver, with or without the PRO logo.
Parts coming soon
If you’ve seen any of to our social media pages lately you’ll see our new aluminium header tank is well on its way with our boost pipe kit following along closely behind. Keep an eye out for updates on these soon.
