Forge Motorsport are excited to launch our RS6 Carbon Fibre Air Box, another superior product to be released in our ‘Hi-Flow’ range.
With this unique sleek design, you can expect to see a carbon fibre housing that flows beautifully along the engine bay, giving you more horse power and torque, and hopefully an appreciation for the care and time that has gone into the production.
- The carbon fibre parts were created from a mould that was hand finished and refined by one of our many skilled craftsmen at Forge Motorsport HQ in Gloucestershire, England.
- The smooth, flowing edges were created from military grade foam.
- The plug was finalised, and a 3D scan was taken enabling us to start the long process of developing the billet tooling for manufacturing.
Once the initial carbon fibre sample was developed, we fitted the intake to the Audi development vehicle for rigorous testing. A few small changes were made to ensure we provide our customers with the best possible fitment and performance.
With the design process complete, we wanted to be sure we delivered the best quality product we could and following the extensive design and development of this intake, we enlisted the services of one the world’s leading carbon fibre manufacturers, whose products range from F1 aero, carbon fibre car bodies, and aircraft wings!
- Rather than using a vacuum (also known as liquid infusion) to draw the resin through the mould then pulling the raw carbon fibre cloth to the mould shape, a technique known as Autoclave is used in the manufacturing of this beautifully designed product. This involves the use of up to 10bar of pressure that is blown into a 100% billet mould to force the material out. This high amount of pressure ensures the carbon fibre is fully in contact with the surface of the mould.
- Therefore, making sure the weave is tight, solid and strong; this process will also ensure there are no imperfections in the product.
- The mould is then heated to cure the resin which in turn gives a tensile strength up to 8 x stronger than mild steel but at a fraction of the weight.
All the Forge Motorsport hoses supplied in this Hi-Flow intake have been designed with 4 layers of ply.
In the development of this intake we also created our own custom moulds for the Forge silicone hoses. This allows for the ease of fitting and transition of flow throughout the air box internal surface.
- The construction of the silicone has been engineered to exceed that of OEM fitments and will enhance any engine bay, both technically and aesthetically.
- The marine grade stainless-steel clamps we supply greatly exceed the OEM plastic clamps. The easily adjustable hex head on them makes for accurate location and easy fitment.
With over 25 years’ experience in both the domestic and motorsport market they recommended a multi-layer foam construction filter, these filters work perfectly in our ‘Hi-Flow’ range. The large filter provided flows 30% more air than the stock filter and fits snuggly within the housing.
Alternatively, you can select our Forge Motorsport designed pleated filter which is excellent on stage 2 tuned cars, as you can see in the dyno sheet, producing over 600 bhp
A completely standard vehicle was sourced for the final dyno testing.
The Forge High Flow airbox produced an impressive 12bhp and 20ftlb increase!
This can be seen in the dyno graph below where the colour blue represents the RS6 with a standard intake and the red representing the same vehicle with our Forge Motorsport ‘Hi-Flow’ intake.
Stage 2 Cars.
Following our initial testing on a stock car we changed the design of the airbox to accommodate the vehicles with a very high state of tune.
Therefore we offer the choice of a foam filter or pleated filter depending on the stage of tune you have.
We recommend our Forge Motorsport pleated filter for a stage 2 tuned vehicle.
The testing was performed at an independent dyno on a well known Audi performance specialists car and was put back to back against the stock airbox with a performance air filter installed.
The Forge airbox continued to perform second to none and gave very good gains at over 700BHP.
The results speak for themselves with a 12BHP gain and 24lbft of torque throughout the rev range resulting in 727BHP and 679lbft.
In The Box:
x1 Forge Motorsport Hi-Flow, carbon fibre intake surround
x1 Pipercross air filter or stage 2 Forge Motorsport pleated filter
x1 Meguiar’s Premium Gold Class Liquid Wax Sachet and Forge Motorsport Micro Fibre Cloth
x1 Silicone Hose (Connecting the Air Box) x2 Silicone Couplers for Audi RS6/RS6 x2 Silicone Couplers for Audi S6/S7
x1 USB with both video and written installation instructions.
This Forge Motorsport product is proudly Engineered for Performance in Great Britain.
*Please note - the Pipercross filter is excluded from the Forge lifetime warranty*
Please watch our video on how to fit an air filter without damaging it.
Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.
All Forge Motorsport products come with a limited lifetime warranty. All warranty claims must be accompanied by the original proof of purchase to enable us to help you. Failure to supply this proof will result in your claim or enquiry being denied.
For further information, please call our customer service team on +44(0)1452 380999 or email firstname.lastname@example.org.
Do not use aggressive (acidic) car cleaning products, particularly traffic film remover solutions or shampoos to clean your intercooler, radiator or oil cooler. The use of these products can damage Forge Motorsport cooling systems and invalidate your warranty. These are often found at car washes. A light, warm, soapy solution (free of harsh acidic cleaning compounds) should be used to clean you cooler and thoroughly rinsed away. We recommend that you should inspect your product on a regular basis for bent and/or crushed fins. Any bent fins should be carefully straightened to allow ambient air to pass through the core face. At the time of installing your Forge radiator, an approved coolant must be used and added to the coolant system. Be sure you never mix coolant and always use distilled water.
This warranty does not apply to any defect in the goods arising from fair wear and tear, wilful damage, accident, negligence by you or any third party, use otherwise than as recommended by the Supplier, failure to follow the Supplier’s instructions, or any alteration or repair carried out without the Supplier’s approval.
Next day delivery applies to orders processed before 2pm Monday to Friday, subject to stock availability and geographical restrictions. 'Next day' refers to next working day. We cannot guarantee next day delivery for orders placed after this time. Full details
DELIVERY IS FREE OF CHARGE FOR ALL ORDERS £20 OR OVER
Products are sent by standard DPD service which is usually a next day service, but can take 2 days in transit. We reserve the right to ship smaller, lower value items via Royal Mail or other service. (Not including Scottish Highlands, Scottish Isles, Northern Ireland, Guernsey, Jersey, and Isle of Man).
Scottish Highlands, Scottish Isles, Northern Ireland, Guernsey, Jersey, Isle of Man, and Cumbria.
Delivery service charge will vary from £15.00 to £26.00. Small sized and low value products are sent by Royal Mail and can take up to 7 working days in transit. All other products are sent by standard UPS/DHL service and can take up to 5 days in transit, but we expect the majority of orders to be delivered within 2 days of dispatch.
Delivery service charges will vary from £10.00 + VAT (20%) to £95.00 + VAT depending on the quantity of product ordered, the related parcel size, and destination postcode. The average charge is approximately £24.00 and the value will be reflected before any charges are incurred during the product selection process.
Orders with a value below £20.00 GBP. Where parcel size permits, orders may be sent by Royal Mail recorded service at the fixed rate of £10.00 GBP + VAT. This will not be reflected at point of order confirmation and this adjustment will be made by the Forge Motorsport sales administration team provided the parcel size is smaller than 50mm high x 300mm long x 300mm wide. This delivery service adjustment will typically be made for low value product below £20.00 GBP + VAT and where the ordered product is small enough to fit in the above-mentioned parcel size.
The Royal Mail recorded service into Europe can take up to 10 working days in transit and tracking number details can be requested via the email@example.com general enquiry email. The Royal Mail tracking number can be entered into the Royal Mail search found in the following tracking service link www.royalmail.com/track-your-item. All other order product will be sent by DHL or UPS standard service taking up to 5 working days in transit.
Delivery service charges will vary from £12.00 to £250.00 GBP depending on the quantity of product ordered, the related parcel size, and destination postcode. The average charge is approximately £24.00 and the value will be reflected before any charges are incurred during the product selection process. Orders with a value below £20.00 GBP. Where parcel size permits, orders may be sent by Royal Mail recorded service at the fixed rate of £12.00 GBP. This will not be reflected at point of order confirmation and this adjustment will be made by the Forge Motorsport sales administration team provided the parcel size is smaller than 50mm high x 300mm long x 300mm wide.
This delivery service adjustment will typically be made for low value product below £20.00 GBP and where ordered product is small enough to fit in the above-mentioned parcel size. The Royal Mail recorded service into Europe can take up to 15 working days in transit and tracking number details can be requested via the firstname.lastname@example.org general enquiry email. The Royal Mail tracking number can be entered into the Royal Mail search engine found in the following tracking service link www.royalmail.com/track-your-item. All other order product will be sent by DHL/UPS standard service taking up to 5 working days in transit.
Whilst shipping outside of the UK may seem expensive, it ensures safe and timely delivery of your new Forge products. For further information on cost and delivery times, please contact Forge using the email@example.com email address if you require any more information. We reserve the right to change the delivery service and company at any time.
Charge Cooler Radiator for the Audi RS6 C7 and Audi RS7
Manufacturer: Forge Motorsport
Charge Cooler Radiator for the Audi RS6 C7 and Audi RS7
Manufacturer: Forge Motorsport