we tried fitting my new intercooler yesterday but it hit the single gas strut and it was also close to the boot lid , we have had to have a re think on the brackets now.
i know from threads on here that the Forge is a tight fit , can anyone tell me how far off the boot lid the top of the intercooler is and is there any problem with engine movement ?
we was also thinking of shorter bobbins , has anyone done this?
If you have a look round lotus talk forum, one chap made an extension to the lower bracket to allow the correct clearence.
Gav
Hi,
when I fitted the forge IC the distance to the boot lid was less than 1 mm. So the IC touched the lid at every alternation of load.
First I made some special adapter sheets to set the boot lid app. 4 mm higher (you can also buy some sheets a Lotus). I my case it is not noticable if you look at the silhouette of the car. But the achieved 5 mm distance was still not enough. Then I contacted forge to get some shorter bobbins. They have a very good service and sent me some within one day for free!
Now I have app. 8-10 mm to the boot lid and it works!
For the single gas strut I made an adapter to set the upper pivot point app. 5 mm higher and app. 5 mm to the rear end of the car. It is okay but the strut still touches the IC a little bit at very hard accelaration.
Some just take off the strut and use a boot prop (read piece of wood 
)
Contact itguy He has just bought and fitted a forge cooler kit from me. He will be able to give details and exact measurements
I put a full write up on here somewhere when I fitted mine as my car was the first single strut car to be fitted with a Forge.
I contacted Forge and got the shorter bobbins and the problem was solved.
I run without a boot strut however it would be usefull if it could be made to fit.
The forge was developed on a twin strut car and because the struts are too powerful they bend the boot upwards in the middle which gives more clearance.
Boothy
A quick pick of the intercooler , it looked beautiful on the car , just need to get it to fit now .
Do tell about the shroud! is that Forge’s work? Does it cost extra?
It’s not a Forge intercooler , it’s a one off , well a two off if the other one is made.
Ahh right, so have u copied a forge or something to need to ask about the height?
Can u get the shrouds made up?
No the intercoolers nothing like a forge really ,it’s bespoke made and bigger than the forge I think , the core is also completely different , I only asked about the forge because I remember reading threads on here how tight the fit was and just needed to know what gap that was needed to clear the boot lid with engine movement .
I had the ally shroud made because the carbon one that I got from RLS is to small so it wouldn’t fit a Forge one.
I think the RLS ones are the same size as the Lotus one which is what the Forge uses.
Does your RLS one have the extra air intakes? if so are you getting rid of it? 
How come you went your own way with the core? Forge did loads of testing and went through quite a few different core designs before chosing the production one, also for obvious reasons you cant go much bigger than the Forge. The Lotus sport one is slightly deeper but not quite as tall but in the testing at CN’s the Forge gave better results.
Boothy
I will be selling the carbon one and yes it has the side ducts .
I can’t really say to much about the core at the moment but it should be good
NA ROCKS 
PMSL at JF’s apparent inferiority complex!!!
[quote=moomin]I will be selling the carbon one and yes it has the side ducts .
I can’t really say to much about the core at the moment but it should be good
[/quote]
Well keep me in mind
Yeah will do , btw what sort of testing on intercoolers did CNs do , also what sort of cores did Forge try ?
Cn’s have dyno’d quite a few of the cars they have converted and the Forge cars have always given the highest results, a good 10bhp over stock and around 6bhp more than the lotus sport.
I do not know the exact details of the intercooler cores they tested, what I know through speaking to Peter at Forge was that they tried quite a few different designs and this one gave the best results on the exige, it has quicker recovery for being heat soked and works well even at low flow rates.
I did plenty of reserch over bar and plate and tube and fin cores but it seems everyone seems to have a different idea on which is the best, the fact Forge did alot of testing on the car was good enough for me and as I had had their stuff before and know its top stuff sold it for me.
Boothy
Sounds good , I only had this made because I wanted the best cooling I could get without the weight of a C/C .
I had the chance of this core and had to wait months for it but I wanted to push the A/A as far as I could .
I can’t say it’s any better than other intercoolers yet because it’s not been tested yet.
When it’s on the car I will data log my IATs and post them .
Cool keep us posted