At Autosport 2005 Forge Motorsport released their uprated Intercooler for the BMW Mini Cooper S. Our development program included the use of many types of Intercooler core and end tank designs. At the initial stages we ran two development projects alongside each other, one an air to air Intercooler and the other an air to water Chargecooler system. The air to air development achieved significantly improved temperature reductions in comparison, which convinced us to solely concentrate on this option. At each stage of development testing was conducted using a vehicle in various states of tune. (With and without, performance software, supercharger reduction pulleys, bonnet scoops and performance air intake systems.). With this Intercooler offering up to a 29% reduction over the original equipment it is a must for those wishing to increase engine power.