Stage 4 Intercooler Kit - Ford Falcon FG

For the Ford FG Falcon enthusiast chasing extreme power figures, thermal management is the ultimate hurdle. While our Stage 3 core has long been a market leader, the Stage 4 Intercooler Kit is pushes the boundary further. 

This is our most aggressive cooling solution, designed specifically for those looking to extract the absolute highest output from the FG platform.

The Ultimate Core

The Stage 4 kit features the largest and most efficient core we have ever offered for the FG Falcon. Built with a high-performance bar and plate design, it offers a level of thermal mass and surface area that is unmatched in the market.

Dimensions: 500 x 425 x 152mm 

Thickness

At a substantial 6 inches deep, this core provides incredible cooling volume, ensuring stable intake air temperatures even under extreme boost pressures and prolonged high-load sessions.

Large-Bore Efficiency

To accommodate the massive volume of air required for elite power levels, the core features 3.5-inch inlets and outlets, minimizing backpressure and maximizing flow.

High-Flow Piping System

To match the capabilities of the Stage 4 core, we have developed a high-volume induction path that eliminates the restrictions found in smaller systems.

3.5-inch Cold Side Piping

This oversized piping ensures that the cooled, dense air has a clear, unrestricted path to the engine, supporting maximum throttle response and top-end power.

3.0-inch Hot Side Piping

Optimised to maintain high air velocity from the turbocharger while providing the flow capacity needed for high-kilowatt builds.

Mandrel-Bent Aluminium

Every pipe is mandrel-bent to maintain a constant internal diameter, ensuring smooth, laminar airflow throughout the entire system.

Professional Hardware and Fitment

This is a complete, high-end hardware package designed for reliability under the most demanding conditions.

Silicone Joiners

The kit includes heavy-duty, multi-ply silicone connectors engineered to withstand high temperatures and extreme boost levels without expansion or leaking.

Stainless Steel Clamps

We provide premium stainless steel hose clamps to ensure a permanent, corrosion-resistant seal across all connections.

End Tanks

The aluminium end tanks are precision-shaped to distribute air across the massive 152mm core depth, ensuring every row of the core is utilized effectively.

The Process West Stage 4 Kit is the definitive choice for the "extreme" Ford FG build. 

By combining a massive 6-inch thick core with a high-flow 3.5-inch induction path, this kit provides the ultimate thermal overhead for world-class horsepower targets.