Following on from our very successful intercooler for the RS3 8v chassis, the Forge intercooler for the TTRS (8S) chassis builds on our reputation for delivering cores that offer real-world increases in power and temperature drops. Whilst the 8V chassis shares many components with the TTRS 8S, the space available behind the bumper is a different shape and the crash bar has also changed. This required a whole new intercooler and crash bar setup for this latest chassis.

The TTRS core is a huge 640x250x100 and of bar and plate design. This gives it a huge 56% more surface area than stock, and an even more impressive 94% increase in volume. The end tanks are made with integrated pipes in order to retain the stock boost hoses, though you can also replace the hoses with our FMKT024 boost hose set if you so wish. Just like on the 8V chassis, we supply a genuine Audi TTRS crash bar which we modify in house in order to accept the new larger core, then finish both the crash bar and core in our standard black crackle finish powder coat for maximum longevity.

As shown in the graph above, for both tests we let the car heatsoak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 36°C), then did a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.

On the stage 1 car we tested on (with map and exhaust modifications), it made 470.5 bhp with a peak intake temperature of 76°C. With just this intercooler fitted and no other modifications, the same car made 520.8 bhp with a peak inlet temperature of 34°C, a gain of 50 bhp and a drop of 41°C. Gains on stage 2 mapped cars will likely be even more impressive as the stock intercooler core really starts to struggle on just stage 1 mapped cars.

The kit contains everything needed for installation including full fitting instructions, which should take around 3-4 hours.

Product Description

• Gains of 10bhp and 10lbft
• Temperature drops of up to 20°C
• Reduced turbo lag, increased response
• Greater overall surface area for greater heat dissipation
• Utilising a race specification tube and fin construction air core
• High flow cast end tanks ensuring optimum air transition for cooling efficiency
• Dyno proven horsepower and torque gains
• A smoother power curve
• Volumetric increase of more than 100%, without additional lag
• Frontal area increase of over 40%
• Includes necessary hardware and instructions for installation
• Lifetime warranty

FMINT25 is a performance intercooler for the Toyota Yaris GR, produced, designed, and tested at our headquarters in Gloucester UK. Throughout the development process we have strived to improve the efficiency and performance of the Yaris GR’s engine. Our project brief was to develop an intercooler utilising all of the available space available in the original position of the OEM intercooler, and to ensure the inlet air temperature is reduced, without any negative effects on the boost pressure or engine and transmission cooling.

Using a combination of scanning software and traditional measuring methods, the design was created. This was then fine tuned by our computational fluid dynamics (CFD) team, and the end tanks were initially created by 3D printers. We then alloy cast our first prototypes from our 3D prints using a sand casting technique and started the testing procedure on several types of intercooler cores.

The first iteration fitted the vehicle perfectly, however, our technicians and engineers felt the inlet and outlet should be enlarged along with providing the end user with the necessary boost pipes to ensure flow was maximized on the Toyota`s GR 3 cylinder engine.

Before getting to work on the dyno, we spec’d three different type of cores; one of these being bar and plate and two being a tube and fin construction – with all three cores having different internal and external fin pitches and configurations. We then welded the test parts ready for testing along with fabricating an internal baffle to the inlet (hot side) of the end tank. This is to ensure, from our CFD research, that the total volume of the core internal is utilised for optimum performance.

Compared to the OEM intercooler, the improved Forge product has a surface area increase of over 42% and an internal volume increase of over 100% as well as Gains of more than 10bhp and 10 lbs/ft. These gains can be even higher depending on your vehicles state of tune and complementing performance products like the turbo inlet adaptor and the inlet duct. As the hot and cold side, inlet and outlet, have been increased to 60mm, we have included within the intercooler kit all the necessary silicone hoses and hardware to complete the installation and connect to the OEM parts.

The Forge Motorsport intercooler is a perfect performance enhancing product that fits directly to the OEM mounting points, making for an easy install, in a relatively short period of time. No cutting of any components are needed, making the installation reversible if the vehicle needs to be returned to stock at any time in the future. The core and end tanks are finished in our black textured anti corrosion coating that also aids with its thermal properties and keeps the product looking that bit more stealthy or OEM+.

The Forge Motorsport lifetime warranty on all hardware products shows the trust we have in the quality of our products while they are being enjoyed on your pride and joy.

Why do we test different cores?

Here at Forge Motorsport, when developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, a tube and fin style core along with different fin pitches and heights e.g. 22 fins per inch or 17 fins per inch, as well as changing the internal fin pitches/shapes and density within the tube enabling to fine tune the amount of pressure drop the intercooler produces.

Pressure drop is not always a bad thing, as our testing and research has proven on various projects. This is because the pressurized air velocity is being stalled by the pressure drop within the cooler thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines as the intercooler reaches its maximum efficiency the turbo has to work a lot harder to force the air through the core. This in turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is over stressed and worked harder.

Having no pressure drop can also prove to be inefficient as the cooler will not lower the charge temperature again resulting in higher inlet air temperatures.

This valve kit allows the fitment of a fast response blow off valve on the VW Up 1.0 TSI/GTI engine.

As the engine does not have a diverter valve fitted as standard, Forge Motorsport have developed a twin piston dump valve that not only gives you an incredibly loud sound when lifting off the throttle but it also increases the throttle response during gear changes by reducing turbo lag, it is designed to help the turbocharger maintain its rotational speed ready for when you accelerate, as well as prolonging the life of your turbo.

• Due to the exposed position of the OEM boost pipe and the nature of an engines heat cycle, the plastic the OEM pipe is made from can deteriorate over time becoming brittle and susceptible to boost leaks. This kit totally replaces this plastic pipe from turbo to manifold with a silicon hose (available in a choice of colours), and everything else you need to install the valve is included in the kit together with full instructions.
  • Anodised CNC machined billet couplers and components along with a tuneable CNC machined twin piston Forge Motorsport valve.
  • Custom colours are available but will incur a 50% none refundable deposit and a lead time of 8-10 weeks.
  • Unlike other valves on the market the Forge valve will not bring on any check engine lights. (EML)
  • The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone. This ensures the colour of the silicon hose stays bright and vibrant and unlike our competitors will not deteriorate over time.
  • Lifetime warranty.

  We cannot guarantee that this product will fit with all aftermarket intakes. Please note if you have the extra spout on your inlet pipe as seen in the picture below then this part will now fit your vehicle

  

  Please note that the 2021 Engine may have some differences due to the map sensor and turbo charger coupler difference, please study the pictures below, if your map sensor and screw type coupler look like this pictured below, FMDV9 and FMDV18 are not compatible. 

  

  

WLTP cars only, (2020+ face lift models with the smooth front badge)

Product Description

With the success of FMINDK30 we took the opportunity to revisit the UP GTI and looked to see if we could improve on the 1.0 TSI air flow to the turbo charger. On investigation we could see that the OEM turbo adaptor was very restrictive and was an area in need for improvement. Therefore, our highly skilled development team got to work designing a solution to maximize the capacity by using our CAD system and physical prototypes.

The OEM plastic turbo inlet includes a restrictive ribbed and hollow noise chamber that is designed to disturb the air flow and reduce induction noise, this OEM part has a detrimental effect to the engines performance especially when tuned. For the best possible gains, we removed the chamber allowing us to increase the volume and air flow significantly. Our hose design also has an internal stepped area where it is positioned and joined to the turbo housing, this is to ensure the transition is as smooth as possible from the inlet tract to the turbo.

Several different designs and material choices were tested until we arrived with the product you see here. The construction of FMTIA3 is manufactured from reinforced multi ply silicone which is more durable than the OEM plastic pipe and it will also not suffer from heat soak like other similar products available. With its enlarged capacity and less restrictive surface area it routes air directly into your turbo charger and allows a greater volume of air to be compressed, this can have a positive effect on accelerating your vehicle after long deceleration or in between gear changes due to more air being kept within the inlet tract to the turbo charger.

This is a product which is essential when tuning the 1.0 TSI engine, if its either stage one or stage two tuning we have seen consistent gains from 3-5 bhp depending on the vehicles state of tune.

This is a straightforward yet very effective power increasing modification that can be fitted with basic tools and has a typical installation time of around 60 minutes. As with all Forge products it includes a full set of comprehensive installation instructions to make fitting as straightforward as possible.

• The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone.
• This means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.
• The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically
• Increased capacity
• No engine check lights (EML)
• Increased air flow
• Lifetime warranty*

Product Description

Please note this product is only compatible with right hand drive vehicles – please read instructions fully before installation

Introducing the Forge High Flow intake hose for the revised 2021 onwards MQB platform 2.0 DNF code engines. This new product replaces the restrictive plastic inlet pipe, with our smooth bore multi-ply silicone hose which increases air flow, improving efficiency and performance. This equates to increases of up to 10hp which is a remarkable gain for an easy to fit bolt on modification.

The Forge developed turbo inlet adaptor improves your vehicles airflow in several ways; designed in a similar way to a conventional velocity stack it routes the air more directly into your turbo charger and allows more air to be compressed due to its larger capacity, this can have a positive effect on accelerating your vehicle after long deceleration or in between gear changes due to more air being kept within the intake system.

The plastic OEM inlet hose has ribs and steps within the bore causing turbulence and disturbing the airflow, the Forge Motorsport Silicone large turbo inlet hose has increased flow over the standard item and testing on the dyno certainly represent the huge benefits from such a well-engineered product.

The Forge Motorsport inlet pipe fits directly to the factory airbox along with most aftermarket performance intakes. On testing the new Mk8 Golf R we found VWs bhp quotes conservative as our results showed 365bhp in complete stock attire.The hours of development and testing are translated into the results you can see on the dyno graph. This is a component which proven below definitely adds extra power.

Testing was completed at Litchfields on a Maha independent dyno, manufactured by the same people who currently supply BMW M sport and Mercedes Benz for all their engine calibration and Dyno testing.

A Simple swap on the dyno to our FMTIA5 proved to enhance power and lower throttle response with gains of 12BHP and 15lb/ft torque at peak RPM along with around 8lb/ft and 8BHP in the midrange.

This is a simple installation and a modification that releases even more power from the VAG motor and fitting takes typically around 40 minutes. As with all Forge products it includes a full set of comprehensive installation instructions to make fitting as straightforward as possible. This product is available in black, blue, red, grey, and a limited-edition alien green.

• Manufactured from 6082 aerospace grade aluminium.
• Black anodised for ultimate protection and durability.
• Increased capacity of over 60%
• No engine check lights (EML)
• Increased air flow
• This means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.
• The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically
• Lifetime warranty

Please read instructions fully before installation

Product Description

Please note this product is only compatible with right hand drive vehicles – please read instructions fully before installation

Introducing the Forge High Flow intake hose for the revised 2021 onwards MQB platform 2.0 DNF code engines. This new product replaces the restrictive plastic inlet pipe, with our smooth bore multi-ply silicone hose which increases air flow, improving efficiency and performance. This equates to increases of up to 10hp which is a remarkable gain for an easy to fit bolt on modification.

The Forge developed turbo inlet adaptor improves your vehicles airflow in several ways; designed in a similar way to a conventional velocity stack it routes the air more directly into your turbo charger and allows more air to be compressed due to its larger capacity, this can have a positive effect on accelerating your vehicle after long deceleration or in between gear changes due to more air being kept within the intake system.

The plastic OEM inlet hose has ribs and steps within the bore causing turbulence and disturbing the airflow, the Forge Motorsport Silicone large turbo inlet hose has increased flow over the standard item and testing on the dyno certainly represent the huge benefits from such a well-engineered product.

The Forge Motorsport inlet pipe fits directly to the factory airbox along with most aftermarket performance intakes. On testing the new Mk8 Golf R we found VWs bhp quotes conservative as our results showed 365bhp in complete stock attire.The hours of development and testing are translated into the results you can see on the dyno graph. This is a component which proven below definitely adds extra power.

Testing was completed at Litchfields on a Maha independent dyno, manufactured by the same people who currently supply BMW M sport and Mercedes Benz for all their engine calibration and Dyno testing.

A Simple swap on the dyno to our FMTIA5 proved to enhance power and lower throttle response with gains of 12BHP and 15lb/ft torque at peak RPM along with around 8lb/ft and 8BHP in the midrange.

This is a simple installation and a modification that releases even more power from the VAG motor and fitting takes typically around 40 minutes. As with all Forge products it includes a full set of comprehensive installation instructions to make fitting as straightforward as possible. This product is available in black, blue, red, grey, and a limited-edition alien green.

• Manufactured from 6082 aerospace grade aluminium.
• Black anodised for ultimate protection and durability.
• Increased capacity of over 60%
• No engine check lights (EML)
• Increased air flow
• This means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.
• The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically
• Lifetime warranty

Please read instructions fully before installation

Please note this product is only compatible with right hand drive vehicles – please read instructions fully before installation

Introducing the Forge High Flow intake hose for the revised 2021 onwards MQB platform 2.0 DNF code engines. This new product replaces the restrictive plastic inlet pipe, with our smooth bore multi-ply silicone hose which increases air flow, improving efficiency and performance. This equates to increases of up to 10hp which is a remarkable gain for an easy to fit bolt on modification.

The Forge developed turbo inlet adaptor improves your vehicles airflow in several ways; designed in a similar way to a conventional velocity stack it routes the air more directly into your turbo charger and allows more air to be compressed due to its larger capacity, this can have a positive effect on accelerating your vehicle after long deceleration or in between gear changes due to more air being kept within the intake system.

The plastic OEM inlet hose has ribs and steps within the bore causing turbulence and disturbing the airflow, the Forge Motorsport Silicone large turbo inlet hose has increased flow over the standard item and testing on the dyno certainly represent the huge benefits from such a well-engineered product.

The Forge Motorsport inlet pipe fits directly to the factory airbox along with most aftermarket performance intakes. On testing the new Mk8 Golf R we found VWs bhp quotes conservative as our results showed 365bhp in complete stock attire.The hours of development and testing are translated into the results you can see on the dyno graph. This is a component which proven below definitely adds extra power.

Testing was completed at Litchfields on a Maha independent dyno, manufactured by the same people who currently supply BMW M sport and Mercedes Benz for all their engine calibration and Dyno testing.

A Simple swap on the dyno to our FMTIA5 proved to enhance power and lower throttle response with gains of 12BHP and 15lb/ft torque at peak RPM along with around 8lb/ft and 8BHP in the midrange.

This is a simple installation and a modification that releases even more power from the VAG motor and fitting takes typically around 40 minutes. As with all Forge products it includes a full set of comprehensive installation instructions to make fitting as straightforward as possible. This product is available in black, blue, red, grey, and a limited-edition alien green.

• Manufactured from 6082 aerospace grade aluminium.
• Black anodised for ultimate protection and durability.
• Increased capacity of over 60%
• No engine check lights (EML)
• Increased air flow
• This means the hoses are suitable to be used with either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.
• The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically
• Lifetime warranty

Please read instructions fully before installation

After discussions with many GR Yaris owners about airbox modifications, Forge Motorsport are proud to release the Toyota Yaris GR Inlet Duct. The Forge inlet duct allows you to add an aesthetically pleasing carbon fibre part to your Yaris GR’s engine bay and help keep your inlet temperatures down during spirited driving and whilst on the track or rally stage.

By utilising 3D scans and SolidWorks CAD, our development team have been able to optimise the size of the inlet duct, creating an increase in uninterrupted cold air to be scooped into the stock airbox. 3D printed test parts were used alongside CAD simulation to ensure the optimum size and geometry. This inlet duct performance car part is much larger than stock with a close fit to the front bumper and airbox to ensure that the heat from the engine causes minimal effect.

During testing on track days, the original duct caused inlet air temperatures to be heavily influenced by heat soak and fluctuated dramatically. Meanwhile the Forge inlet duct kept the inlet air temperatures not only reduced but at a more consistent temperature. A reduced consistent temperature is of great importance because any high temperature peaks will cause the ECU to retard the ignition and reduce the power you have available. The Forge inlet duct design incorporates a free-flowing path to both the upper and lower opening of the airbox, whereas the stock design has no flow management to the lower opening and the upper is small and not fully sealed. It is worth understanding that the lower opening is of far greater importance to the performance of your Yaris GR. There is a vacuum operated flap which is activated when under full throttle conditions, therefore the Forge Motorsport Inlet Duct ensures that your Yaris is getting colder directed air when the engine needs it the most.

Data was collated and logged live by a passenger on a track day running in conjunction with an aftermarket intercooler on a 5 lap open pit session back to back against the stock inlet scoop (another 5 lap session). Inlet air temps had been reduced from 42°C to between 35 and 36°C. We even saw temperatures of up to 45°C on the stock duct. Fluctuation between temperatures on the stock inlet duct were greatly improved when air was fed to the secondary inlet scoop via the composite Forge Motorsport inlet feed.

With the OEM design including open sections, baffles, and noise restrictors to disrupt the airflow, the inlet duct is part of our acclaimed Hi Flow range and will ensure that your Yaris is getting critical cold air. Not only is the Forge part a better option for performance, but the carbon fibre really helps to give the engine bay some character. The high-quality carbon fibre is prepreg 2×2 twill formed in an autoclave from billet tooling and finished with an anti UV gloss gel coat. The Forge Motorsport lifetime warranty on all hardware products shows the trust we have in the quality of our products while they are being enjoyed on your pride and joy.

This valve kit is an evolution of the FMARSDV dump valve we market for the 8P chassis RS3. It was developed for those who have tuned, or plan to tune, their 8S chassis Audi TTRS or 8V chassis Audi RS3 in excess of 450hp. Audi have seen fit to not change the design of the OEM dump valve from the previous RS3, so the same issues are carried over to the new 8V chassis, namely it was observed that cars over 450bhp were randomly getting errors from the stock solenoid dump valve not functioning. Whilst the stock valve will operate as designed, with the boost level necessary for 450bhp the stock valve couldn’t move the volume of air it needed to, so the ECU was seeing too great a positive boost in the MAP readings between gear changes and assuming the stock valve wasn’t functioning correctly.

We looked closely at this issue, and noted that there would be no real fix for this as the size of the hole for the valve is too small in the stock elbow. We decided that we would re-design and produce our own elbow, allowing a much larger DV port, which in turn would allow fitment of a larger valve to take advantage of it. We also improved the internal flow of the elbow and removed restriction within the valve. The elbow design has been changed by Audi to accommodate a different throttle body, so our design has changed too.

*Please note this WILL NOT fit 2019 engine DNWA

With the engine management on this engine being MAP based rather than MAF based, which is unlike many other Audi engines, we have also incorporated the option into the kit, of being able to run as a recirculation valve or with an atmospheric discharge/blow off.

Pair of silicone boost hoses for the Audi RS6/RS7 C8. Forge Motorsport designed these hoses so they can withstand pressures that can be experienced on tuned and re-chipped engines. They will long outlast the original hoses and with our limited lifetime warranty on all Forge products, you can be sure these hoses won’t let you down.

• The Forge silicone hoses in this kit have been designed to include an expensive inner liner of modified silicone known as Fluorosilicone.
• This means the hoses are suitable to be used with  either modern long-life coolants, Organic Acid Technology coolants (O.A.T.) or air containing oil mist.
• The construction of the hoses has been engineered to exceed that of the OEM fitments, and will enhance any engine bay both technically and aesthetically
• The use of a Fluorosilicone liner ensures that Forge silicone hoses are the clear market leader.
• Lifetime warranty*