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Thread: AH Fab / Ebay / Forge S3/A3 FMIC installs (image heavy)

  1. #201
    RIP S3dave

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    Quote Originally Posted by AHFabs View Post
    You are OK with the 63 mm, in fact 60 mm tube is OK for around 620 BHP.

    Once you go over 680 BHP it would be good to go to 76 mm the you should be OK for a good 750 + BHP which if it is genuine power and not pub horse power will be savage on you tyres but great fun

    Alex.
    oh its savage all right.. spins all 6 gears at any time in dry on full chat
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  3. #202
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    finished off today got it pressure tested by a friend and its fine, both pipes sit level with bumper and sit back a little so dont stick out
    Only problem now is i think the turbo gone as it making a noise which it did before but i thought i had a leaking boost pipe so cracked on with the front mount hoping it would solve it, it hasnt so can only think its a new turbo time gonna take tip of on sat and have a look see ifs it damage in any ways etc
    13.8 santapod gti fest 2010 class g 1st place winner. A3 1.8 20vt 180 quattro, Revo stage 2.5 map,[/B] Forge tip, forge cold side, Forge splitter valve, Carbonio cold intake with aem filter,decat pipe, 2.5inch exhaust, k03s turbo with forge actuator, revs fmc with forge houses, j n75 valve, 4 bar fuel reg, hid's, 17" tt alloys t1r



  4. #203
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    Hi everyone, Im new here.

    First and foremost great thread. I was wondering if you guys have pictures of the intercooler piping for the hot side(ie compressor's outlet to intercooler), more specifically where the pipe goes from the LH underside of the car.

    thanks in advance.
    Last edited by flatshifter; 2nd January 2010 at 21:26.

  5. #204
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    what is the bnefit of relocating the dump valve, thanks in advance

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    finally all finish took a while to get pipe sitting right but happy with it overall
    Last edited by quattro rob; 2nd January 2010 at 23:54.
    13.8 santapod gti fest 2010 class g 1st place winner. A3 1.8 20vt 180 quattro, Revo stage 2.5 map,[/B] Forge tip, forge cold side, Forge splitter valve, Carbonio cold intake with aem filter,decat pipe, 2.5inch exhaust, k03s turbo with forge actuator, revs fmc with forge houses, j n75 valve, 4 bar fuel reg, hid's, 17" tt alloys t1r



  7. #206
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    Alright everyone, im just wondering if you need to buy a new hose from intercooler to the throttle body? or if you can use the existing?

    any other tips and advice when fitting it would be handy, thanks

  8. #207
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    can use existing 1 m8, the hose i fitted is the cold side kit from forge vbut you dont need it
    13.8 santapod gti fest 2010 class g 1st place winner. A3 1.8 20vt 180 quattro, Revo stage 2.5 map,[/B] Forge tip, forge cold side, Forge splitter valve, Carbonio cold intake with aem filter,decat pipe, 2.5inch exhaust, k03s turbo with forge actuator, revs fmc with forge houses, j n75 valve, 4 bar fuel reg, hid's, 17" tt alloys t1r



  9. #208
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    I got the turbo revs kit, wasn't ready for the lack of MAP sensor + N75 take off mounting points. Got someone to weld a flange for the MAP and made a t-piece to sort the N75. As people have pointed out, I wasn't too impressed with the pipes sticking out like a sore thumb either, so I wrapped them in black silicon, looks better IMO



    Pic of it fitted in engine bay...




    Anyway, I'm wanting to return the car to standard now, so the entire kit will be for sale if anyone wants it?

    I'm also after the original hoses from the system if anyone wants to sell theirs? I butchered mine stupidly so don't have them anymore. So if anyone's fitted a kit and has some spare I'll gladly send some money your way

  10. #209
    MIKE GTR's Avatar
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    I've got a forge front mount on mine. My question is, is it right that the 2 standard intercoolers remain either side and that the forge just sits in line or should the 2 standard ones be removed?

  11. #210
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    The two standard SMIC should be removed i think. So you now have three intercoolers! lol
    Alex S3 AMK
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  12. #211
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    remove the standard ones or else you'll have a biger surface area resulting in increased unecessary lag....plus the FMIC will do loads more than both the other two so they really arent needed....ALSO you'd be extremely lucky if you could fit the FMIC with them inline as its too tight for the FMIC on its own....only one person has managed to keep the drivers side one, but he went to forge and they customised a golf cooler..... not needed though so stick to just the FMIC
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  13. #212
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    Quote Originally Posted by 1animal1 View Post
    remove the standard ones or else you'll have a biger surface area resulting in increased unecessary lag....plus the FMIC will do loads more than both the other two so they really arent needed....ALSO you'd be extremely lucky if you could fit the FMIC with them inline as its too tight for the FMIC on its own....only one person has managed to keep the drivers side one, but he went to forge and they customised a golf cooler..... not needed though so stick to just the FMIC
    Its there already, fitted, with both the standard ones still there. It was on the car when i got it and i must admit i thought it strange, the car isn't laggy at all but there must be a pressure drop

  14. #213
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    ah sorry fella, misread what ya wrote..... thats strange.....bit of a weird pipe set up? or have the fogs gone?
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  15. #214
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    Nope front fogs are there and it fits ok, not the best i must admit, but its in no probs at all

  16. #215
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    U can see it a little bit in this pic

  17. #216
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    Hi everyone,

    does anybody know have pictures of the n75 valve or any information on how or where is best to fit it?

    any info it helpfull

    cheers

  18. #217
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    No pics mate, but you need an 8mm brass nipple that you can just drill and screw into the pipework for the N75 take off. Then just seal it up with some chemical metal to ensure it's air tight (the pipes are pretty thin so it doesn't really 'thread' nicely.

    Fit it wherever you like really, although it's generally thought that the closer to the turbo the better the response Stick the first pipe onto the turbo, take a look at what you've got and decide where's best. I put mine about 3'' up the pipe, facing towards the drivers side to avoid any clearance issues around the tight TIP side.
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    i took mine to a alloy welder near me, cut off and blanked were the dump valve should go and welded a 8mm nipple to the other side, pressure tested and it holded 30 psi fine all for the sum of 15, job done
    13.8 santapod gti fest 2010 class g 1st place winner. A3 1.8 20vt 180 quattro, Revo stage 2.5 map,[/B] Forge tip, forge cold side, Forge splitter valve, Carbonio cold intake with aem filter,decat pipe, 2.5inch exhaust, k03s turbo with forge actuator, revs fmc with forge houses, j n75 valve, 4 bar fuel reg, hid's, 17" tt alloys t1r



  20. #219
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    Ok cheers lads, I think what im going to do is use the piece of pipe thats on the first fmic pipe coming off the turbo, just reduce the hose pipe size to fit. As im fitting a cold side kit at the same time, shud be alright.

    Any body got any info on a gd boost gauge and boost controller my mate got a 15 EBAY one it works fine.

  21. #220
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    loving the work on all these cars. but 1 thing i dont understand is why do you all go for massive sized intercoolers when less than half of it is exposed to a direct air flow? Surely if you had smaller sized intercoolers (with the same depth core) you would not only save your self money, reduce lag (all be it by a tiny amount), but still have the same effect as those big jap intercoolers you are all fitting??

    Sorry to sound a gimp but but i honestly dont understand why? it seems a waist of a huge intercooler to me.

    just for the record i apreciate the work involved.. I know hands down they can be a pain to fit!


    sits back and waits for a grilling..

    Now to many mods to list! Lots of power, torque and Leather!

  22. #221
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    nice to see a little tussle now and again

    My opinion as a consumer is that Forge appears to produce quality products, however i would catagorise what they do as over kill with charging to match..... I am a firm believer that you get what you pay for, but because Alex's cooler is cheaper does not automatically mean the Forge item is better...... the only way to be conclusive is to test side by side which isn't realistically gonna happen.....

    Essentially with the majority of applications on this site in particular, I dont think your looking at the market where we are trying to push every last bit of flow through......i for one would trust Alex's judgement based on his experience in this field for the sake of making the seemingly huge saving over the Forge item - one of the major selling points of the Forge item is that it is a 'kit' which you would think would mean it would be 'easier to fit' - the past few fitments however haven't gone together as smoothly as i would personally like to enjoy after parting with such a ridiculous sum of money - AH fabrications for me once i've decided to part with my cash

    Tim
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  23. #222
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    You will notice that there is a certain height to the intercoolers that does not correspond to the air inlet hole. They have to have the height to allow enough cooling air tubes for the required mass air flow to produce the power.

    Large frontal area will always be preferred over a smaller frontal area using a thicker core because the air speed needed to go through a core over 60 mm thick will need forward speeds to average 90 MPH average to work properly.

    If the core is designed properly, there will be gains in cooling by radiation and even the reduced air speed around the intercooler will still take heat away if the core is made with rows light enough not to suffer from heat soak.

    Cheerz,

    Alex.

  24. #223
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    now this is an awesome thread, just read through the hole thing.. TOP JOB to all of you who have contributed to it....I am really enjoying this forum..

    Alex(AH Fabs) is there anyway you could ship one of those intercoolers over to Greece? could I pay through paypal?
    thanks

  25. #224
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    Quote Originally Posted by SteveBAM View Post
    now this is an awesome thread, just read through the hole thing.. TOP JOB to all of you who have contributed to it....I am really enjoying this forum..

    Alex(AH Fabs) is there anyway you could ship one of those intercoolers over to Greece? could I pay through paypal?
    thanks
    Hi Steve,

    Yes we can send it to you, if you send me your full address details, I will be able to get a carriage price to you. Pay pal will be no problem. My email address is: ahfabrications@mac.com

    Cheerz,

    Alex.

  26. #225
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    Alex

    Do the intercoolers come with mounting brackets welded on or is that something we have to do? Also is the price still the same as tuffty mentions in the first post, 250

    Cheers

    Sam

  27. #226
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    Quote Originally Posted by AHFabs View Post
    Hi Steve,

    Yes we can send it to you, if you send me your full address details, I will be able to get a carriage price to you. Pay pal will be no problem. My email address is: ahfabrications@mac.com

    Cheerz,

    Alex.
    ok thanks Alex i will contact you soon..

  28. #227
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    Quote Originally Posted by S View Post
    Alex

    Do the intercoolers come with mounting brackets welded on or is that something we have to do? Also is the price still the same as tuffty mentions in the first post, 250

    Cheers

    Sam
    Hi Sam,

    It will come with the fixing brackets welded on, and the price is still 250.00 + 15.00 delivery if payment is done as a gift in Paypal. If you send me your Email address I will send a photo.

    Many thanks,

    Alex.

  29. #228
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    got home from work today sun was shining so thought i would start fitting my forge fmic.
    and i must say well worth the money imo everything went straight on where it was ment to the bumper went on first time which i was very supprised after other comments on this kit, 100% happy with things so far
    will post some pics when ive finished as none of the hoses are secured yet


    SOLD 2002 S3,full black heated leather, bose, 997 turbo's, lcr splitter, coilovers, superchip, blueflame cat back, k&n, forge dv, forge hoses, forge quickshift, forge rear tie bars and forge fmic

  30. #229
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    this is an ebay intercooler kit for lcr i brought cost me 200 quid tiged welded 2 brackets on fitted like a dream was a bit wary about its perfromace but amd told me it worked spot on when they mapped the car kept the temps down and had good flow


  31. #230
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    Gav ...,glad you liked the Forge intercooler , regarding the ebay cores ...there is some good info over on seatcupra.net posted by Rob Don that will show that some of the ebay core are less than efficient when it comes to the actual cooling ....its all about choice tho

  32. #231
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    any chance that you will bring the cost of yours down Forge? owing to the fact that i can source an AH and pipes for sub 400, 250 for convenience is one hell of a premium still
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  33. #232
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    The Forge kit is designed as straight fit , it includes a new crash bar already cut and modified to accept the Forge intercooler ....I can offer you a discount off the RRP

  34. #233
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    forge, am i losing efficiency by having both the std coolers and your forge cooler working together
    I'm not normally a praying man, but if you're up there, save me Superman

  35. #234
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    I would imagine so yes m if you are on a standard turbo , I would thik that you will be getting a lot of pressure drop ... our developed intercooler was taking into consideration the removal of the oem parts

  36. #235
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    Its got a k04 hybrid, but to be honest it keeps blowing the hoses off the intercooler joins, so there appears to be a presure build up at these points. do u sell the end pipes on their own and if so how much?

    many thx
    I'm not normally a praying man, but if you're up there, save me Superman

  37. #236
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    sorry we only seel the Forge kit as a complete kit

  38. #237
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    OKey doke cheers.

    The original owner of mine must have binned those lol
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  39. #238
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    Quote Originally Posted by Forge View Post
    Gav ...,glad you liked the Forge intercooler , regarding the ebay cores ...there is some good info over on seatcupra.net posted by Rob Don that will show that some of the ebay core are less than efficient when it comes to the actual cooling ....its all about choice tho
    totally spot on less than an hour i had the old stuff off and new stuff test fitted bumper whent straight on then i ran out of light lol
    will hopefully have the car back 2gether in no time and it was done in my little garage without jacking the car up
    Last edited by s3gav; 2nd March 2010 at 18:34.


    SOLD 2002 S3,full black heated leather, bose, 997 turbo's, lcr splitter, coilovers, superchip, blueflame cat back, k&n, forge dv, forge hoses, forge quickshift, forge rear tie bars and forge fmic

  40. #239
    It's all in bits

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    Spent some time this afternoon getting my car ready to fit my AH Fabs FMIC. The plan was to get the crash bar measured up so I can take it to my mates workshop and get it cut tomorrow. Anyway I took the bumper off and decided to remove both SMIC and their related pipe work. I then moved the horns and got the crash bar off so that everything was out of the way and I could offer up the FMIC to see what would needed to be chopped out.

    However it then struck me that my S3 (99 APY) is completely different to all others I have seen (without the bumper on at least) as I have a naff looking silver rad, which has a ruddy great fan bolted on the left of it, and what looks to be some component of the AC strapped in behind the crash bar on the right.



    What seems strange though is that on the back of the radiator there is a circular shaped hole that looks like it should have fan in it but that doesn't - well there are 2 holes, but one does have a fan in.

    Has anyone else come across this arrangement and can offer some tips? I am hoping I should be able to fix AC thing somewhere else but I'm not sure what to do about the fan as I don't think I can clear it.

  41. #240
    RIP S3dave

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    someones been bodging on your car
    front fan aint std. 2 fans on back is
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