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Discussion Starter #1 (Edited)
Levels Performance is proud to offer our front mount intercooler upgrade for the Fiesta ST! This is a direct bolt in requiring no modification.


- 18" x 6.5' x 3.25" bar and plate core
- Less than 1.5 psi pressure drop
- Direct fit
- 6061 aluminium end tanks, CNC cut and tig welded
- 6061 mandrel bent connecting pipes
- Uses factory charge pipes

We will be updating the information as we complete testing and release more photos of the setup installed. As of now the intercooler is available for Pre-order!




 

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Very interested to see hp gains and increased flow numbers over stock
 

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What are the advantages of going with an aftermarket intercooler? I'm new to the Fiesta community and don't know much about the OEM setup. By replacing the IC with a bigger unit, don't you sacrifice flow vs attaining cooler temperatures? Any info is appreciated.
 

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Superly fly often with aftermarket coolers you get better flow in addition to greater size for better cooling. Generally the sacrifice is a bit of boost lag, but in modern cars, its not much at all. The positives outweigh the negatives. The larger inter cooler allows you to push more boost as well. A larger i/c by itself won't do too much for power, but the cooler temps will help eliminate any pinging or detonation from high heat.
 

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OP says the pressure drop is less than 1.5psi. Does this mean peak boost numbers are dropped by 1.5psi? if so, less boost would make less power? no? I understand the additional cooling will cool the air charge and make more power, it would be interesting to see some dyno numbers with "just" the intercooler and nothing else. Thanks. .... BTW, how would I make a new "paragraph" on this forum. "enter" doesn't do anything :(
 

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Superly fly often with aftermarket coolers you get better flow in addition to greater size for better cooling. Generally the sacrifice is a bit of boost lag, but in modern cars, its not much at all. The positives outweigh the negatives. The larger inter cooler allows you to push more boost as well. A larger i/c by itself won't do too much for power, but the cooler temps will help eliminate any pinging or detonation from high heat.
This is true, except I don't see pushing much more boost out of the stock set up. Ford already has it push 21.5psi. With the motor being over 10:1 compression I don't see adding much more boost. I'll have to wait and see some testing before I order a new intercooler for a bolt-on modded FiST.
 

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Discussion Starter #13
What are the advantages of going with an aftermarket intercooler? I'm new to the Fiesta community and don't know much about the OEM setup. By replacing the IC with a bigger unit, don't you sacrifice flow vs attaining cooler temperatures? Any info is appreciated.

Our intercooler is designed to provide maximum cooling efficiency without adding more volume to the intake tract than necessary. Our design actually improves flow while dropping charge air temperatures drastically.
 

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Discussion Starter #14
OP says the pressure drop is less than 1.5psi. Does this mean peak boost numbers are dropped by 1.5psi? if so, less boost would make less power? no? I understand the additional cooling will cool the air charge and make more power, it would be interesting to see some dyno numbers with "just" the intercooler and nothing else. Thanks. .... BTW, how would I make a new "paragraph" on this forum. "enter" doesn't do anything :(

The 1.5 psi pressure drop estimate refers to the flow as the charge air passes through the core of the intercooler. I can best explain this by asking you to imagine the air traveling through the charge pipe up to the intercooler, and once it hits the core it must find its way through the channels. This is where the pressure drop MAY occur, due to the fact that the air must pass through several small channels. Think of it in terms of flow restriction.

I hope this helps explain!

Nik @ Levels
 

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How does this intercooler compare to the Mountune? The Mountune costs $300 more so that's clearly favoring the Levels Performance option. Not saying one is better, just asking if there's a comparison of one to the other? I ask this mostly because I'm coming from NA performance cars and I've never really messed with a turbo car before.

Thanks.
 

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Looking at all of the aftermarket intercoolers available and there is probably at least 6 or so including the UK offerings, Levels Performance appear to be the only ones that have actually made the core smaller in length and used mandrel bent piping to achieve a straight inlet tank design. The standard intercooler with its plastic end tanks and shape 90 inlets are a poor compromise Ford has chosen and definitely reduce the performance of the intercooler. Replacing the OEM Fist intercooler is one of the first things I would do to increase performance.
 

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Discussion Starter #19
Looking at all of the aftermarket intercoolers available and there is probably at least 6 or so including the UK offerings, Levels Performance appear to be the only ones that have actually made the core smaller in length and used mandrel bent piping to achieve a straight inlet tank design. The standard intercooler with its plastic end tanks and shape 90 inlets are a poor compromise Ford has chosen and definitely reduce the performance of the intercooler. Replacing the OEM Fist intercooler is one of the first things I would do to increase performance.

As Sekred said, our design improves the factory core by creating a straight-through passage for the charge air in the core. For instance, our Focus ST intercooler upgrade yields charge air temps of as low as 5 degrees over ambient (this means that our intercooler is cooling the charge air to the point where it is almost the same temperature as the outside air).

I can can guarantee that our intercooler upgrade will provide very impressive results at a more reasonable price point. All of our intercoolers are hand tig welded and QA checked before being sent out.

and to answer the questions about our Fiesta on the dyno, that run was 100% factory :)
 

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