Stage 2 Intercooler Upgrade Kit - Ford Falcon BA/BF
The Process West Stage 2 Kit is the definitive choice for BA/BF owners moving beyond basic modifications. It combines a high-volume core with optimised piping to ensure your engine receives a steady supply of cool, dense air.
The Ford BA/BF Falcon is a powerhouse platform, but as power levels rise, so does the heat generated by the turbocharger. The Process West Stage 2 Intercooler Upgrade Kit is a comprehensive solution designed to provide the thermal headroom necessary for high-performance street and track applications.
High-Efficiency Core Design
The heart of this kit is a substantial bar and plate intercooler core. This design is chosen for its superior thermal mass, allowing it to soak up and dissipate heat rapidly during high-boost scenarios.
Dimensions: 500 x 360 x 80mm
Surface Area: The 80mm thickness offers a massive increase in cooling volume compared to factory units, preventing the "heat soak" that often kills power during spirited driving.
Cast End Tanks: The core features high-flow aluminium end tanks. These are shaped to ensure air is distributed evenly across the internal cooling rows, maximizing every millimeter of the core’s surface.
Precision Plumbing
Cooling the air is only half the job; getting it to the engine efficiently is the other. This kit replaces restrictive factory rubber hoses with a dedicated piping solution.
Mandrel Bent Aluminium: Our piping is mandrel bent to ensure a constant internal diameter. This eliminates the turbulence and restrictions found in traditional "crush-bent" pipes.
Improved Throttle Response: By smoothing out the air path and using rigid aluminium, the system reduces expansion under boost, leading to more immediate throttle response.
Installation and Reliability
This is a complete "turn-key" hardware kit. We provide everything required to secure the system and ensure it performs reliably under high pressure.
Reinforced Silicone Joiners: The kit includes high-grade silicone connectors designed to withstand high temperatures and significant boost levels without leaking or bursting.
Stainless Steel Clamps: Every connection is secured with heavy-duty stainless steel hose clamps for a permanent, corrosion-resistant seal.