The Ford Falcon BA/BF platform is renowned for its tuning potential, but as boost levels increase, so does the demand for effective heat dissipation.

The Process West Stage 2 Intercooler Core is designed as a high-performance upgrade for owners looking to move beyond the limitations of the factory cooling system.

Core Construction

The Stage 2 kit utilises a rugged bar and plate design.

This construction is favored for high-performance street and track applications due to its ability to soak up and dissipate heat rapidly while remaining durable against road debris.

Dimensions: 500 x 360 x 80mm

Thermal Mass: The 80mm thickness provides a substantial increase in volume over standard units, allowing for much higher power levels before heat soak becomes an issue.

Efficiency: Designed to maintain low pressure drop, ensuring that the increase in cooling doesn't come at the expense of throttle response.

Performance Application
While the Stage 1 core is excellent for mild upgrades, the Stage 2 is the preferred choice for enthusiasts aiming for higher horsepower targets. It provides the necessary thermal headroom to keep intake temperatures stable during repeated hard acceleration or sustained high-speed driving.

Note: Due to the increased dimensions of the Stage 2 core, this unit is typically used in conjunction with upgraded piping kits to ensure maximum flow and reliable fitment.

Stage 2 Front Mount Intercooler Core — Ford Falcon FG

The Process West Stage 2 is a significant step up from the factory intercooler for the Ford Falcon FG, delivering improved charge air cooling and a solid foundation for mid-to-high level performance builds.

Substantial core, improved cooling. At 420 x 410 x 90mm, this bar and plate core offers a meaningful increase in cooling surface area and overall volume over the factory unit. Lower intake air temperatures translate to more consistent power, improved throttle response, and greater detonation resistance under hard driving.

Bar and plate construction. Bar and plate cores are chosen for their superior heat dissipation and heat soak resistance over tube and fin alternatives. Under sustained hard driving, the Stage 2 continues to perform where the factory core falls short.

Supports mid-to-high power levels. The Stage 2 core is well suited to modified FG Falcon builds running increased boost and power, offering genuine cooling capacity for street and occasional track use without stepping up to the full Stage 3 dimensions.

Finish options. Available in black powder coat or silver finish to suit your build.

A proven intercooler core upgrade for the Ford Falcon FG.

The Process West Stage 2 Front Mount Intercooler Kit is a complete cooling upgrade for the Ford Falcon FG, combining a high-performance core with everything needed for a clean, integrated installation.

Core specifications. The 420 x 410 x 90mm bar and plate core features high-flow polished aluminium end tanks, delivering smooth airflow and effective charge air cooling with a meaningful increase in capacity over the factory unit.

Complete kit. Mandrel bent aluminium piping, all necessary silicone joiners, and stainless steel hose clamps are included for a fully integrated, factory-quality finish.

Finish options. The intercooler core is available in black powdercoat or silver finish to suit your build.

A proven cooling upgrade for the serious FG Falcon build.

The Process West Stage 2 Piping Kit delivers superior airflow performance for the Ford Falcon FG, featuring mandrel bent aluminium piping throughout for smooth, unrestricted flow between the intercooler and engine.

Complete kit. All necessary silicone joiners and stainless steel hose clamps are included for a clean, integrated installation.

Compatibility.

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.

STAGE 2 INTERCOOLER CORE
The Process West Stage 2 Front Mount Intercooler Core for the Ford BA/BF Falcon is a 500 x 360 x 80mm bar & plate core, with hi-flow polished aluminium end tanks. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

CROSS OVER PIPE KIT
This crossover pipe is designed to work with the Process West Stage 2 Intercooler Kit and Under Battery Cold Air Intake. It can also be paired with the "around the battery" Intercooler Piping Kit which will enable fitting of the under battery cold air intake even with the stock intercooler in place.

The upgrade crossover does 2 things:

Removes the factory restrictive cross over pipe
Allows fitting of the Process West Under Battery Cold Air Intake
This product opens the door for a great package that consists of the Stage 2 Intercooler Kit, Cold Air Intake and Crossover.

Also worth noting is the bonnet clearance above the crossover. I have made the unit as large as possible but still left 10mm clearance to the bonnet... something which can not be done with bent aluminium tube (it can be done but you a left with a very awkward looking pipe).

UNDER BATTERY COLD AIR INTAKE
Our air intake system is designed to be used in conjunction with our billet plenum or in other custom set ups. It utilises the space normally taken by the factory intercooler plumbing under the battery tray.

Note: This intake is not designed to work if the factory intercooler is still in place.

STAGE 2 INTERCOOLER CORE

The Process West Stage 2 Front Mount Intercooler Core for the Ford BA/BF Falcon is a 500 x 360 x 80mm bar & plate core, with hi-flow polished aluminium end tanks. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

THROTTLE BODY RE-LOCATION KIT

The throttle body relocation was developed for a few reasons:

• To have the shortest possible intercooler piping length which gives maximum throttle response.
• To give a very neat engine bay appearance.
• To have a true 3 inch intercooler pipe size without bonnet rubbing issues. We have found that running 3 inch piping over the top of the engine into the factory throttle body position will cause rubbing on the under side of the bonnet.

All components that make up the throttle body relocation. Relocating the throttle body means that the wiring to the throttle body must be extended but for ease of installation we have developed these plug-in patch harnesses.

UNDER BATTERY COLD AIR INTAKE

Our air intake system is designed to be used in conjunction with our billet plenum or in other custom set ups. It utilises the space normally taken by the factory intercooler plumbing under the battery tray.

Note: This intake is not designed to work if the factory intercooler is still in place.

STAGE 2 INTERCOOLER CORE
The Process West Stage 2 Front Mount Intercooler Core for the Ford BA/BF Falcon is a 500 x 360 x 80mm bar & plate core, with hi-flow polished aluminium end tanks. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

THROTTLE BODY RE-LOCATION KIT
The throttle body relocation was developed for a few reasons:

To have the shortest possible intercooler piping length which gives maximum throttle response.
To give a very neat engine bay appearance.
To have a true 3 inch intercooler pipe size without bonnet rubbing issues. We have found that running 3 inch piping over the top of the engine into the factory throttle body position will cause rubbing on the under side of the bonnet.
All components that make up the throttle body relocation. Relocating the throttle body means that the wiring to the throttle body must be extended but for ease of installation we have developed these plug-in patch harnesses.

BATTERY RELOCATION KIT
The Process West battery relocation kit has been developed to move the existing battery from the factory position to give clearance for large air box installations.

Our unique system re-locates the existing battery, mounting it behind the factory foglight area on the drivers side of the car. The reason this position was chosen was to keep the battery cables as short as possible, as long cables cause high voltage drop and poor starting performance.

The installation of the system is very simple and does not require cutting of any cables. You simply install the new laser cut battery tray and bracket, and mount the new plastic battery terminal distribution block (high density P7000) then connect the cables.

The method of extending the battery cables means no cutting and still gives easy access for jump starting/charging if needed.

4 INCH RACE AIR BOX
Our 4in race air box system has been designed for extreme power levels. Utilizing the area normally occupied by the battery we have been able to design the ultimate high horse power intake.

The air box uses a massive 6in internal diameter K&N filter which mounts onto a 6in to 4in bell mouth which connects to a internally wire re-enforced molded silicon hose down to the turbo. This combination gives maximum flow for power levels of 500rwkW+.

The air box can also be used for high mount turbo configurations. The 4in OD air box outlet is at the approximate height of most high mount turbo compressor inlets so a simple section of pipe is all that is needed to use the air box for high mounts.

For those that have upgraded their turbo to a 4in inlet (0.7A/R cover) we offer a 4in to 4in silicon hose. (PWBACAI03-hose)

This hose simplifies the installation of larger turbos. The hose can be purchased separately or part of an initial air box purchase.

STAGE 2 INTERCOOLER CORE
The Process West Stage 2 Front Mount Intercooler Core for the Ford BA/BF Falcon is a 500 x 360 x 80mm bar & plate core, with hi-flow polished aluminium end tanks. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

PLENUM CHAMBER
The Process West Plenum of the BA/BF Falcon is CNC Machined to precision from solid billets of 5083 aluminium plate. Billet aluminium is super strong and holds enormous amounts of pressure, nothing but the best for Process West. To promote perfect air flow into the cylinder head each runner entry has a blended bell-mouth. The plenum is supplied with a plug-in throttle body extension wiring loom to allow for installation with no wire cutting, as well as teh option for custom cover plates.

UNDER BATTERY COLD AIR INTAKE
Our air intake system is designed to be used in conjunction with our billet plenum or in other custom set ups. It utilises the space normally taken by the factory intercooler plumbing under the battery tray.

Note: This intake is not designed to work if the factory intercooler is still in place.

STAGE 2 INTERCOOLER CORE
The Process West Stage 2 Front Mount Intercooler Core for the Ford BA/BF Falcon is a 500 x 360 x 80mm bar & plate core, with hi-flow polished aluminium end tanks. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

PLENUM CHAMBER
The Process West Plenum of the BA/BF Falcon is CNC Machined to precision from solid billets of 5083 aluminium plate. Billet aluminium is super strong and holds enormous amounts of pressure, nothing but the best for Process West. To promote perfect air flow into the cylinder head each runner entry has a blended bell-mouth. The plenum is supplied with a plug-in throttle body extension wiring loom to allow for installation with no wire cutting, as well as teh option for custom cover plates.

BATTERY RELOCATION KIT
The Process West battery relocation kit has been developed to move the existing battery from the factory position to give clearance for large air box installations.

Our unique system re-locates the existing battery, mounting it behind the factory foglight area on the drivers side of the car. The reason this position was chosen was to keep the battery cables as short as possible, as long cables cause high voltage drop and poor starting performance.

The installation of the system is very simple and does not require cutting of any cables. You simply install the new laser cut battery tray and bracket, and mount the new plastic battery terminal distribution block (high density P7000) then connect the cables.

The method of extending the battery cables means no cutting and still gives easy access for jump starting/charging if needed.

4 INCH RACE AIR BOX
Our 4in race air box system has been designed for extreme power levels. Utilizing the area normally occupied by the battery we have been able to design the ultimate high horse power intake.

The air box uses a massive 6in internal diameter K&N filter which mounts onto a 6in to 4in bell mouth which connects to a internally wire re-enforced molded silicon hose down to the turbo. This combination gives maximum flow for power levels of 500rwkW+.

The air box can also be used for high mount turbo configurations. The 4in OD air box outlet is at the approximate height of most high mount turbo compressor inlets so a simple section of pipe is all that is needed to use the air box for high mounts.

For those that have upgraded their turbo to a 4in inlet (0.7A/R cover) we offer a 4in to 4in silicon hose. (PWBACAI03-hose)

This hose simplifies the installation of larger turbos. The hose can be purchased separately or part of an initial air box purchase.

For the Ford BA/BF Falcon enthusiast pushing the absolute limits of the chassis, thermal management is the difference between consistent power and engine-saving timing pull. The Process West Stage 3 Intercooler Core is engineered specifically for high-horsepower builds that demand maximum cooling capacity without compromising airflow.

The Stage 3 core represents a massive jump in cooling volume. Aside from our flagship Stage 4 unit, this is the largest and most efficient intercooler available for the BA/BF platform today.

Dimensions: 500mmm  425mm 100mm

100mm Thickness

The substantial 100mm depth provides an enormous thermal mass, allowing the core to remain effective even during prolonged high-boost sessions or competitive use.

Bar and Plate Construction

We utilise a premium bar and plate design, chosen for its durability and its superior ability to dissipate heat rapidly compared to standard tube-and-fin alternatives.

Max Airflow

A core of this size requires precise air distribution to function effectively. We have focused on the internal dynamics to ensure the charge air is cooled evenly as it passes through the unit.

High-Flow Cast End Tanks

The aluminium end tanks are shaped to direct air across the entire internal surface area. This prevents "hot spots" and ensures that every millimetre of the 425mm height is utilised for cooling.

Efficiency at Scale

Despite its massive size, the internal core geometry is optimised to maintain low pressure drop, ensuring your turbocharger doesn't have to work harder to move air through the system.

Performance Application

The Stage 3 core is designed for vehicles that have moved well beyond basic bolt-on modifications. It is the ideal choice for owners targeting high-kilowatt figures who require a cooling solution that will not "heat soak" after a single pass or spirited run.

Vehicle Compatibility: Fits all 2002–2007 Ford Falcon BA/BF models.

System Integration

This core is designed to be the centerpiece of a high-flow induction system, providing the densest, coolest air charge possible to the engine.

If you are building a high-power BA/BF Falcon and need a cooling solution that offers maximum surface area and depth, the Stage 3 core is the professional choice. It balances massive cooling potential with the high-end fit and finish Process West is known for.

Stage 3 Front Mount Intercooler Core — Ford Falcon FG

The Process West Stage 3 is the largest and most efficient front mount intercooler core available for the Ford Falcon FG (besides our Stage 4), and a proven foundation for any serious performance build.

Massive core, serious cooling. At 500 x 425 x 100mm, this bar and plate core offers a significant increase in cooling surface area and overall volume compared to the factory unit. More core means lower intake air temperatures, and lower intake air temperatures mean more consistent power, improved throttle response, and a safer tune with greater detonation resistance.

Bar and plate construction. Bar and plate cores are chosen for their superior heat dissipation and heat soak resistance over tube and fin alternatives. Under sustained hard driving, the Stage 3 continues to perform where lesser cores fall short.

Supports serious power levels. The generous core dimensions and smooth internal flow path give this intercooler the capacity to support the horsepower goals of even the most demanding FG Falcon builds, from street-driven performance cars through to dedicated track and drag applications.

Finish options. Available in black powder coat or silver/raw finish to suit your build.

The definitive intercooler core upgrade for the Ford Falcon FG.

Stage 3 Intercooler Upgrade Kit — Ford Falcon FG

The Process West Stage 3 Intercooler Upgrade Kit brings the proven performance of our BA/BF Stage 3 core to the FG platform, with revised end tanks engineered specifically for the FG engine bay. This is the largest and most efficient complete intercooler kit available for the FG Falcon.

Massive core, serious cooling. At 500 x 425 x 100mm, this bar and plate core delivers a substantial increase in cooling surface area and volume over the factory unit. Lower intake air temperatures mean more consistent power, improved throttle response, and greater detonation resistance under hard driving.

Complete piping kit. Includes 2.5-inch hot side intercooler piping and 3-inch cold side intercooler piping, complete with a new 3-inch high-flow cast elbow at the throttle body for maximum flow from core to engine.

Flexible intake compatibility. Compatible with both the Process West 4-inch Race Air Box and the factory air intake system, making it a straightforward upgrade regardless of your current intake setup.

The definitive intercooler upgrade for the serious FG Falcon build.

The Process West Stage 3 Intercooler Upgrade Kit is engineered for high-horsepower Ford BA/BF Falcons (2002–2007) that require the absolute maximum in thermal management.

Aside from our flagship Stage 4, this is the largest and most efficient cooling solution available for the Falcon platform, designed to support elite power levels while maintaining rock-solid intake temperatures.

Core Dimensions

At the heart of this kit is a massive bar and plate intercooler core, built to handle extreme boost pressures and high-volume airflow without heat soaking.

• Dimensions: 500 x 425 x 100mm

• Massive Thermal Capacity: With a 100mm thickness, this core provides an enormous surface area for heat exchange, ensuring your engine receives the densest, coolest air charge possible.

• High-Flow Cast Tanks: The aluminium end tanks are shaped to distribute air evenly across the entire 425mm height of the core, eliminating "dead spots" and maximising cooling efficiency.

High-Flow Piping

To complement the massive core, we have redesigned the entire charge-air path using mandrel-bent aluminium piping. This ensures a constant internal diameter for smooth, laminar airflow.

Staged Piping Diameters

The kit features 2.5-inch hot-side piping to maintain air velocity from the turbo, stepping up to 3-inch cold-side piping to provide high-volume flow to the engine.

Throttle Body Relocation

A standout feature of the Stage 3 kit is our unique throttle body relocation. This optimizes the intake path, significantly reducing the overall length of the piping for sharper throttle response and improved engine bay aesthetics.

Comprehensive Installation Kit

This is a complete, professional-grade hardware solution. We provide every component necessary to install and secure the system for long-term reliability.

Multi-Ply Silicone Joiners

High-grade silicone connectors are included to withstand extreme temperatures and high boost pressures without expansion or failure.

Stainless Steel Clamps

The system is secured with heavy-duty stainless steel hose clamps, ensuring a permanent, leak-free seal.

Mandrel Bends

All aluminium piping is mandrel bent to prevent the flow restrictions common with standard pipe-bending techniques.

The Stage 3 Upgrade Kit is the definitive choice for BA/BF owners pushing for serious power figures. By combining our massive 100mm core with a specialized throttle body relocation and optimised piping, this kit provides the ultimate balance of cooling capacity and flow efficiency.

STAGE 3 INTERCOOLER CORE
The Process West Stage 3 Front Mount Intercooler Core for the Ford BA/BF Falcon includes a 500 x 425 x 100mm bar & plate core, which is the largest and most efficient intercooler for the BA/BF Falcon on the market today. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

THROTTLE BODY RE-LOCATION KIT
The throttle body relocation was developed for a few reasons:

To have the shortest possible intercooler piping length which gives maximum throttle response.
To give a very neat engine bay appearance.
To have a true 3 inch intercooler pipe size without bonnet rubbing issues. We have found that running 3 inch piping over the top of the engine into the factory throttle body position will cause rubbing on the under side of the bonnet.
All components that make up the throttle body relocation. Relocating the throttle body means that the wiring to the throttle body must be extended but for ease of installation we have developed these plug-in patch harnesses.

UNDER BATTERY COLD AIR INTAKE
Our air intake system is designed to be used in conjunction with our billet plenum or in other custom set ups. It utilises the space normally taken by the factory intercooler plumbing under the battery tray.

Note: This intake is not designed to work if the factory intercooler is still in place.

STAGE 3 INTERCOOLER CORE
The Process West Stage 3 Front Mount Intercooler Core for the Ford BA/BF Falcon includes a 500 x 425 x 100mm bar & plate core, which is the largest and most efficient intercooler for the BA/BF Falcon on the market today. This allows for smooth flow and effective cooling of the charge air entering the engine.

The intercooler core is available in both black powdercoated or silver finish

THROTTLE BODY RE-LOCATION KIT
The throttle body relocation was developed for a few reasons:

To have the shortest possible intercooler piping length which gives maximum throttle response.
To give a very neat engine bay appearance.
To have a true 3 inch intercooler pipe size without bonnet rubbing issues. We have found that running 3 inch piping over the top of the engine into the factory throttle body position will cause rubbing on the under side of the bonnet.
All components that make up the throttle body relocation. Relocating the throttle body means that the wiring to the throttle body must be extended but for ease of installation we have developed these plug-in patch harnesses.

BATTERY RELOCATION KIT
The Process West battery relocation kit has been developed to move the existing battery from the factory position to give clearance for large air box installations.

Our unique system re-locates the existing battery, mounting it behind the factory foglight area on the drivers side of the car. The reason this position was chosen was to keep the battery cables as short as possible, as long cables cause high voltage drop and poor starting performance.

The installation of the system is very simple and does not require cutting of any cables. You simply install the new laser cut battery tray and bracket, and mount the new plastic battery terminal distribution block (high density P7000) then connect the cables.

The method of extending the battery cables means no cutting and still gives easy access for jump starting/charging if needed.

4 INCH RACE AIR BOX
Our 4in race air box system has been designed for extreme power levels. Utilizing the area normally occupied by the battery we have been able to design the ultimate high horse power intake.

The air box uses a massive 6in internal diameter K&N filter which mounts onto a 6in to 4in bell mouth which connects to a internally wire re-enforced molded silicon hose down to the turbo. This combination gives maximum flow for power levels of 500rwkW+.

The air box can also be used for high mount turbo configurations. The 4in OD air box outlet is at the approximate height of most high mount turbo compressor inlets so a simple section of pipe is all that is needed to use the air box for high mounts.

For those that have upgraded their turbo to a 4in inlet (0.7A/R cover) we offer a 4in to 4in silicon hose. (PWBACAI03-hose)

This hose simplifies the installation of larger turbos. The hose can be purchased separately or part of an initial air box purchase.

STAGE 3 INTERCOOLER CORE
The Process West Stage 3 Front Mount Intercooler Core for the Ford BA/BF Falcon includes a 500 x 425 x 100mm bar & plate core, which is the largest and most efficient intercooler for the BA/BF Falcon on the market today. This allows for smooth flow and effective cooling of the charge air entering the engine.

PLENUM CHAMBER
The Process West Plenum of the BA/BF Falcon is CNC Machined to precision from solid billets of 5083 aluminium plate. Billet aluminium is super strong and holds enormous amounts of pressure, nothing but the best for Process West. To promote perfect air flow into the cylinder head each runner entry has a blended bell-mouth. The plenum is supplied with a plug-in throttle body extension wiring loom to allow for installation with no wire cutting, as well as teh option for custom cover plates.

UNDER BATTERY COLD AIR INTAKE
Our air intake system is designed to be used in conjunction with our billet plenum or in other custom set ups. It utilises the space normally taken by the factory intercooler plumbing under the battery tray. Note: This intake is not designed to work if the factory intercooler is still in place.