Stage 3 Intercooler Core - Ford Falcon BA/BF

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.