The allotted space in the Fiesta is tight for an uprated intercooler. Anything larger (taller) would compromise the cooling system (cooling package) by blocking airflow to the radiator thereby increasing the coolant temps. Once that happens the timing is pulled and the performance suffers dramatically. Trust me when I tell you we have tested just about every configuration possible on the car coupled with all of the OE data we have access to and this is the best solution up to 230-250bhp. The stock Fiesta intercooler is about the same size as the stock Focus ST and that power unit produces significantly more power than the 1.6L. So the stock overall size is not too bad for the 1.6L Our core is tube and fine and the intercooler core has been increased in surface area and the end tanks have been reduced to allow the unit to package correctly. This then increases the cooling efficiency of the total package compared to that of the OEM unit. No drill installation. We also have an uprated intercooler pipe set coming next month. It's designed to have about a 2kPa pressure drop. The perfect complement to our MR 23(?) upgrade. It will be interesting to see the data at the track next weekend.