FORGE Intake (CAI) - Full Write Up: Buying/Fitting/Results

[Iggu]

Iggu : sorry for the hi-jack

Hey no worries - if it means more S3s get Forge CAIs and kick BMWs into touch its all good !

Check out my other thread about "Revo + Milltek + Forge = RS3": proof that the Forge adds around 10bhp on its own. A quality addition to any S3. All credit to Rabbit222: he made me do it !!

 

[whiteunderarm]

Hey bru...only reason im doing the CAI is coz i dont wanna get left for dead by all you other S3 boys If we all agreed to keep our cars stock standard just imagine how much money we could save But nooooo...im forced to keep up with the pack and be poor hehehe

 

[boggym]

Damian, any update on how much longer to wait. Still keen to get my hands on one.

 

[325Psi]

Geez, so all of us in sunny South Africa will all be running software and CAI. To the poor oke it the stock 135i/335i........ he's going to wonder WTF if he tries racing us

Iggu : sorry for the hi-jack

I gort something for you doc!

 

[ved789]

I gort something for you doc!

oh no nooooot you {bowing down} !!!!!!! Your 335 will annihilate my low life S3

As a side note ; did u run your S3 against your 335i, with the intake on the S3 ?

 

[sakkie69]

Does DPM ship to South Africa, or does our location exclude us from the group buy.

If the price from DPM (including shipping and possible custom) is equivalent to the FRC price, then I wouldnt mind ordering from them instead purely due to the backlog at FRC. It's a pipe and a cone, not much can do wrong (touch wood!)

Oh yeah, speaking of cones, this uses a dry filter. Where do you get replacements from, from Forge? What size does it take?

 

[Scorpius]

Cool thanks for the updates guys. Hopefully the EVOMS intake will be ready by then and so my problem will deciding between the Forge and the EVOMS kit.

Yeah looks CAI is a must. I must say I was a little underwhelmed with the S3 stock (note that in SA we get the detuned 188kW version) but when chipped it felt like what I imagined the S3 should've felt like. Thought I'd be happy for a good while but not so. Just hope I can stay well satisfied for a while after the CAI lol

 

[325Psi]

oh no nooooot you {bowing down} !!!!!!! Your 335 will annihilate my low life S3

As a side note ; did u run your S3 against your 335i, with the intake on the S3 ?

Yeah, we did that test. It's tight up to 140km/h. Then from 140 to 240 the 335 pulls about 6-8 lengths.

 

[DPM]

3 - 4 weeks i'd say but if you want want you'll have to be quick as they're only getting a certain amount in and then you'll have to wait for the next batch.

Yeah we can ship to South Africa but it won't be cheap!

Damian @ DPM

 

[Forge]

Right guys, we had withdrawn the IND02-S3 from sale as a few customer had reported fitting problems, specifically with the hard pipe coming into contact with the battery. We had Saf's car in on tuesday (2007 model) and had no issues. Even the heat shield fitted fine, though we are going to trim them a little from now on to ease the fitting. We can only conclude that the fitting issues occur on the 2008 model with the revised TSI engine, hence we have added it back to the website, but with a note that it wont fit 2008+ models. We need to see a 2008 model to confirm what modifications are necessary. Im going to re-do the instructions too, as its apparent that the fittng instructions (for a MKV Golf) aren't specific enough for the S3.

Incidentally, as asked in one of the posts above, we can supply the filters seperately if necessary, just ask your nearest Forge dealer, or us directly.

Any questions, drop me a PM.

 

[ved789]

Right guys, we had withdrawn the IND02-S3 from sale as a few customer had reported fitting problems, specifically with the hard pipe coming into contact with the battery. We had Saf's car in on tuesday (2007 model) and had no issues. Even the heat shield fitted fine, though we are going to trim them a little from now on to ease the fitting. We can only conclude that the fitting issues occur on the 2008 model with the revised TSI engine, hence we have added it back to the website, but with a note that it wont fit 2008+ models. We need to see a 2008 model to confirm what modifications are necessary. Im going to re-do the instructions too, as its apparent that the fittng instructions (for a MKV Golf) aren't specific enough for the S3.

Incidentally, as asked in one of the posts above, we can supply the filters seperately if necessary, just ask your nearest Forge dealer, or us directly.

Any questions, drop me a PM.

Thank you for this. When will the stock be available ?

 

[Forge]

We're short on hoses at the moment, only black in stock - red and blue are being made as i type. Everything else is in stock at the moment.

 

[S3 SAF]

Hey Chris
im really pleased with my CAI and d/v thanks once again for the these items you fitted for me its transformed the sound of the car dramatically and pulls stronger and the car feels a bit more responsive. A definet must for all you guys.....
p.s when should i be expecting the black hoses chris...?
Saf

 

[Forge]

PM'd you.

 

[block]

Im just wondering if you mean cars registered in 2008 or model year 2008? my car is a 57 but is a my08 model year, will it fit?

Also while your about, im still concerned about the filter being mounted so low down in uk conditions is it definately ok? seeing as our summers are almost as wet as our winters now.

Paul

 

[Macs]

The year of registration does not mean anything (what if a car produced in 2006 sits at the dealer's and is sold and registered only in 2009?). It's all about the model year or the year of production. Best thing to do is to check the engine code, if yours is CCTA or CBFA you have to wait for the new CAI

 

[Forge]

Im just wondering if you mean cars registered in 2008 or model year 2008? my car is a 57 but is a my08 model year, will it fit?

Also while your about, im still concerned about the filter being mounted so low down in uk conditions is it definately ok? seeing as our summers are almost as wet as our winters now.

Paul

Its MY08 - check your engine code as suggested. Its the change in the engine thats the problem.
As for the filter, we've not had a single one back or any complaints. We had one on our own MKV Golf last year in the floods of July (and round here was the worst hit area of all) and it was fine. Its quite possible that the location its in could see the filter get wet, but the intake path is very long so it doesnt present a problem. You can always build a shield behind the foglight if you are bothered - the filter would still suck in much cooler air than in the engine bay. Easy to do too, as you can just pull the foglight trim off to make the shield.

 

[block]

The year of registration does not mean anything (what if a car produced in 2006 sits at the dealer's and is sold and registered only in 2009?). It's all about the model year or the year of production. Best thing to do is to check the engine code, if yours is CCTA or CBFA you have to wait for the new CAI

Is that as in the engine number, mines bhz if that sounds right?

 

[block]

Hey Chris
im really pleased with my CAI and d/v thanks once again for the these items you fitted for me its transformed the sound of the car dramatically and pulls stronger and the car feels a bit more responsive. A definet must for all you guys.....
p.s when should i be expecting the black hoses chris...?
Saf

Get some pics up saf:thumbsup:

 

[Fast,not furious]

Right guys, we had withdrawn the IND02-S3 from sale as a few customer had reported fitting problems, specifically with the hard pipe coming into contact with the battery. We had Saf's car in on tuesday (2007 model) and had no issues. Even the heat shield fitted fine, though we are going to trim them a little from now on to ease the fitting. We can only conclude that the fitting issues occur on the 2008 model with the revised TSI engine, hence we have added it back to the website, but with a note that it wont fit 2008+ models. We need to see a 2008 model to confirm what modifications are necessary. Im going to re-do the instructions too, as its apparent that the fittng instructions (for a MKV Golf) aren't specific enough for the S3.

Incidentally, as asked in one of the posts above, we can supply the filters seperately if necessary, just ask your nearest Forge dealer, or us directly.

Any questions, drop me a PM.

Hi,i just thought i'd let you know i had the same fitting issues on mine,which is an S3 8P,late 06 build,as well as the rubbing on the battery moulding,i had to bend the heatshield,and the OE filter cover mounts wouldn't hold it in place. I've had to replace them,and inverted some M6 bolts,with a locking nut below the heatsield,followed by a large washer either side,and another nut secured with threadlock. I also used rubber pads to stop any vibration. The last thing i've had to do is replace the bolt which secures the alu intake pipe to the engine block with a longer one and fit spacer washers,again with thread lock as it kept vibrating loose/falling out!

No issues with water and filter yet though,although i am getting a Hydroshield,just in case! It might be worth noting that some S3's have a plastic shield behind the fog grill (mine doesn't) Could it be the newer models now intake the air from the lower bumper intake?

Hope this helps.

Gary

ps can the filter be cleaned,or will it need replacing,and if so,at what intervals would you recommend - bearing in mind it's a sod to get to! I guess it's there for performance gains,opposed to practicality,which is why all other CAI filters are in the engine bay?

pps i'm absolutely loving the performance and sound this thing produces! Thanks guys

 

[mikenbn]

Hey Guys,

Loved the idea of this so decided to order one - However decided not to run the pod that low under the bonnet - seeing an R32 with a similar set-up have its rod bent as a result of water getting in made me think twice.

I did like the idea of having proper intake plumbing instead of the engine cover redirect.
Decided to use my existing BMC since it was enclosed - also invested in some cool cover heat shield from DEI.

Throttle response has increased quite significantly and spool comes up earlier which means more torque down low. All in all very happy with the Mod.

 

[Iggu]

Its MY08 - check your engine code as suggested. Its the change in the engine thats the problem.
As for the filter, we've not had a single one back or any complaints. We had one on our own MKV Golf last year in the floods of July (and round here was the worst hit area of all) and it was fine. Its quite possible that the location its in could see the filter get wet, but the intake path is very long so it doesnt present a problem. You can always build a shield behind the foglight if you are bothered - the filter would still suck in much cooler air than in the engine bay. Easy to do too, as you can just pull the foglight trim off to make the shield.

The apparently "empty" space behind the passenger side foglight grill is NOT empty at all and neither water nor air can get directly to the Forge air intake. This is a common misconception. About one inch behind the honeycomb grill is a solid moulded plastic air channel which directs air at the gear box and engine block. You could literally stand and fire a hosepipe at that foglight grill and no water could come into contact with the Forge intake whatsoever. To get the filter wet you would have to submerge the front end of the car in water and allow it seep in through the wheel arch or the headlight unit. I bought and fitted a Hydroshield buut its pretty unnecessary to be honest.

 

[block]

The apparently "empty" space behind the passenger side foglight grill is NOT empty at all and neither water nor air can get directly to the Forge air intake. This is a common misconception. About one inch behind the honeycomb grill is a solid moulded plastic air channel which directs air at the gear box and engine block. You could literally stand and fire a hosepipe at that foglight grill and no water could come into contact with the Forge intake whatsoever. To get the filter wet you would have to submerge the front end of the car in water and allow it seep in through the wheel arch or the headlight unit. I bought and fitted a Hydroshield buut its pretty unnecessary to be honest.

Sounds good to me iggu , once i get my misfire solved im having one.

 

[tobycruse]

The apparently "empty" space behind the passenger side foglight grill is NOT empty at all and neither water nor air can get directly to the Forge air intake. This is a common misconception. About one inch behind the honeycomb grill is a solid moulded plastic air channel which directs air at the gear box and engine block. You could literally stand and fire a hosepipe at that foglight grill and no water could come into contact with the Forge intake whatsoever. To get the filter wet you would have to submerge the front end of the car in water and allow it seep in through the wheel arch or the headlight unit. I bought and fitted a Hydroshield buut its pretty unnecessary to be honest.

As this is the case, where does the Forge get its cold air from?

 

[Iggu]

As this is the case, where does the Forge get its cold air from?

It isn't exactly an airtight space in there !
When its raining and I put my coat hood up my head stays dry - but I don't suffocate.
Sorry to be facetious but you know what I mean.

 

[tobycruse]

It isn't exactly an airtight space in there !
When its raining and I put my coat hood up my head stays dry - but I don't suffocate.
Sorry to be facetious but you know what I mean.

Lol!

 

[Fast,not furious]

Guys....it depends when your car was produced...mine's an early S3 8P,Dec 06 build,and there's no plastic diverter behind the passenger side fog grill,so cold air has a more direct path.

I guess the bods at forge figured that way down there would be a lot cooler than where the OE intake is (on mine it's above the rad,on newer models it sucks it in from channels below the rad) I've had no probs with water ingress,even in our torrential downpours this summer,and apparently the design is such that water would have hell of a job getting up there anyway!

 

[Rabbit222]

Right guys, we had withdrawn the IND02-S3 from sale as a few customer had reported fitting problems, specifically with the hard pipe coming into contact with the battery. We had Saf's car in on tuesday (2007 model) and had no issues

I've had this issue on mine, modified a bracket somewhat and fitted it...will take a pic of mine and show you what was done.

 

[Rabbit222]

All credit to Rabbit222: he made me do it !!

LOL, don't blame me...I live by the motto, DO IT..JUST DO IT!

 

[block]

Well ive decided to order myself one of these from damian at dpm complete with the hydroshield for when my car is finally fixed by audi.
so does anybody fancy a brand new bmc pannel filter pm me if your interested.

 

[hatmeow]

Guys,

I have heard that the CAI (or any intake mod that replaces the original panel filter) seriously affects the life of the airflow sensor as it was not made for such a high flow. Is this true? any one having problems with the airflow sensor?

 

[block]

Guys,

I have heard that the CAI (or any intake mod that replaces the original panel filter) seriously affects the life of the airflow sensor as it was not made for such a high flow. Is this true? any one having problems with the airflow sensor?

i wouldnt have thought that the airflow was that much faster with these, its more to do with how cool the air is coming into the engine than the speed id have thought.
No one whos running one on here has had any problems so far anyhow afaik.

 

[hatmeow]

If it is improving the throttle response and the spool I would think that it must have something to do with the increased airflow.

However, if no one is experiencing dead MAFs shortly after their CAI install I guess its worth a shot!

 

[Iggu]

Over 2k miles with mine and no problems whatsoever.

 

[block]

Well i thought id beter update this thread seing as i now have my car back and fitted my forge intake kit last night.

It was a fairly simple job but time consuming for what it is, the hardest bit was getting in behind the wheel arch liner tbh and fitting the heatshield above the turbo. The heat shield is a bit badly shaped and the holes in it should be smaller so you could mount it with 10mm bolts as opposed to the original air filter mounting posts which are a pain to remove and replace.

Once fitted tho its a good looking bit of kit and i much prefer to be able to see the actuall engine than a plastic cover.

Out on the road it has the sound i was after with a subtle blow off sound in there too, plus if you drive sensibly you can pretty much not hear it.

Performance wise the car now feels as quick as it did with the remap on so i cant wait to get that installed and see the difference.

Overall chuffed to bits with it and i would recommend it to anyone with an s3 unless you already think the original car is too noisy. it is £300 quid well spent ( that includes a water shiled for the filter.) and thanks to damian again at dpm for sorting me out.

Paul

 

[whiteunderarm]

Just finished fitting my Forge intake and all i can say is WOW! Huge improvement over the standard "box" and the car seems much more responsive...spool up seems to take a tad bit longer but im assuming this is due to the increased length of the pipe...overall though a worthwhile mod! :thumbsup:

Oh and as for fitting it yourself...tough! I now have wat seems like 2 missing fingers!

 

[Iggu]

Just finished fitting my Forge intake and all i can say is WOW! Huge improvement over the standard "box" and the car seems much more responsive...spool up seems to take a tad bit longer but im assuming this is due to the increased length of the pipe...overall though a worthwhile mod! :thumbsup:

Oh and as for fitting it yourself...tough! I now have wat seems like 2 missing fingers!

Do you have the standard exhaust ? If so when you fit a 3" downpipe that spool up delay will disappear as will the rev-hanging you're probably seeing. The Forge sucks up so much air that it can't get out of the standard exhaust quick enough - a full TBE completes the airflow.

 

[whiteunderarm]

Do you have the standard exhaust ? If so when you fit a 3" downpipe that spool up delay will disappear as will the rev-hanging you're probably seeing. The Forge sucks up so much air that it can't get out of the standard exhaust quick enough - a full TBE completes the airflow.

Yip...still running standard exhaust...the exhaust upgrade is next on my list!

 

[KRL]

Which is better then - forge or EVOMS?

 

[Iggu]

Which is better then - forge or EVOMS?

Ha ha. You won't get an impartial answer to that one from anyone so I'll start things off. Forge.
Has anyone actually managed to buy an Evoms yet ?
Or seen any data to prove what they offer ?