Stage 3 Intercooler Upgrade Kit - Ford Falcon BA/BF

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.