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Old 07-25-2011, 06:11 PM   #1
Sean@forge
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Forge MK6 Golf R Development Thread

Forge Motorsport UK was recently granted access to a customer's MK6 Golf R for development purposes. We have a full range of products in the works, and we will have all of it finished and available prior to the car's arrival stateside, so that you can fully outfit your car with a full range of products immediately upon taking delivery, if you so desire.



As many of the hardware upgrades will carry over from the existing FSI engine found in the MK5 GTI, much of our development is already done, and will require little more than confirmation of fitment, so we anticipate having the full compliment of hardware upgrades done very soon.

The car in question belongs to a Revo Technik software customer as well, and is already tuned using Revo's Stage 2 software tuning, and is outfitted with a Milltek full turbo-back exhaust system. The car is otherwise bone stock.

Here is a link to the baseline dyno with the above-mentioned upgrades.

http://farm7.static.flickr.com/6142/...c7fdc9ee_o.jpg

Clearly visible on the graph is some ignition timing pull as well as the intake air temperatures, showing that the car can definitely benefit from some intake and cooling upgrades.

Below is a list of all of the products that we have planned, and items in bold are confirmed:

- Forge TWINtake twin filter induction system
- Forge WINtake single filter induction system (cheaper entry level option)
- Forge TWINtercooler dual front mounted intercooler system
- Forge Blow-off valve adapter / spacer
- Forge Replacement DV upgrade
- Forge Replacement atmospheric blow-off valve upgrade
- Forge PCV bypass / Oil Catch Tank kit
- Forge K04 upgraded wastegate actuator
- Forge Boost gauge fitting kit
- Forge 6-speed front to back short shift linkage (up to 40% reduction)
- Forge 6-speed side to side short shift linkage (up to 40% reduction)
- Forge Big Knob shift knob
- Forge DOT-approved stainless braided Teflon brake lines
- Forge 330mm (13") 6-piston big brake kit
- Forge 356mm (14") 6-piston big brake kit
- Scorpion full turbo-back stainless steel exhaust system with high flow cat ("street")
- Scorpion full turbo-back titanium cat-less exhaust system ("race")

I will continue to keep this thread updated as our development progress continues.

Last edited by Sean@forge; 09-30-2011 at 11:58 AM.
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Old 07-25-2011, 06:21 PM   #2
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If only I could afford an R..
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Old 07-25-2011, 06:26 PM   #3
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First up was the development of the TWINtake intake system.



On a bone stock vehicle, the stock airbox does a fairly decent job of providing adequate airflow, so one will generally experience minimal power gains from an intake on an otherwise stock car. Once the car is tuned, however, and is often producing anywhere from 50-100% of additional boost pressure over stock, the factory airbox and filter will become a restriction and limit airflow.

One high flow air filter will certainly show an improvement, however, the surface area of that filter will still only flow a given amount of air. Our unique twin carbon fiber enclosed filter design provides for the largest surface area of filtering element to provide for the greatest possible level of airflow regardless of the level of tune of the vehicle.

We have long since proven this design on the transverse 2.0 FSI and TSI engines of the MK5 and MK6 GTI's, as well as numerous other vehicles. We were more than confident that the same, if not better gains could be realized on the Golf R, and we've done exactly that!

Our dyno test was conducted on the exact same day as the above baseline dyno. In fact, the car was never removed from the dyno to swap out the intakes. It remained strapped down the entire time, and the tests were conducted back to back.

Here is a link to the 2nd dyno of the TWINtake intake system:

http://farm7.static.flickr.com/6017/...6877d6b3_o.jpg

Here is a link of the two graphs overlayed:

http://farm7.static.flickr.com/6022/...3291620c_o.jpg

Gains in power and torque are evident throughout the entire power band, with peak gains as high as 17 hp realized at some RPM levels, with a broader and more usable torque curve as well. You can also clearly seen a slight reduction in inlet temperatures as well as less ignition timing pull. This will only improve further with our TWINtercooler upgrade.

The Forge TWINtake for the MK6 Golf R will be available soon!

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Old 07-25-2011, 06:33 PM   #4
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good god.
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Old 07-25-2011, 08:23 PM   #5
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If only I could afford an R..
I can, I just don't want to. (serious) But thats a thread on its own.

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good god.
for real, this looks fucking beastly. Nice job, Mike / Forge.
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Old 07-25-2011, 08:50 PM   #6
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good god.
+1
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Old 07-26-2011, 09:48 AM   #7
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Old 07-26-2011, 09:57 AM   #8
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Mike. But the TWINtercooler will be only for non-DSG R's right? Because i have DSG and on left side where one of the ic hose is supposed to be, it's the DSG oil cooler. Are you also considering making a version for DSG R's?

Thanks
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Old 07-26-2011, 10:15 AM   #9
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Mike. But the TWINtercooler will be only for non-DSG R's right? Because i have DSG and on left side where one of the ic hose is supposed to be, it's the DSG oil cooler. Are you also considering making a version for DSG R's?

Thanks
As I said above, Forge UK is doing the development currently as the car is not yet available in the US, so I have no firsthand involvement in it right now. You would need to e-mail or call Forge UK.

With that said, we have already done a TWINtercooler fitment for the US-spec TTS which also has the secondary radiator/cooler, and the hoses clear this part just fine with the removal of the shroud/ducting, so I see no reason for the Golf R DSG application to be any different. I'm fairly certain this particular vehicle has a manual transmission, so I would guess they have not seen a DSG equipped car yet to look at this specifically, but we will investigate it as soon as we can.
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Old 07-26-2011, 10:43 AM   #10
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Thanks Mike. I'll keep an eye on this thread.

Cheers
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Old 07-26-2011, 11:39 AM   #11
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Hey would you be able to post
A video of that exhaust system? I had no idea that scorpion made exhausts for the golf r

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Old 07-26-2011, 11:57 AM   #12
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Hey would you be able to post
A video of that exhaust system? I had no idea that scorpion made exhausts for the golf R
The systems have not been created yet.

We will post the details as soon as we get to that stage of the development.
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Old 07-26-2011, 12:11 PM   #13
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Mike, can you speak with the guys at Scorpion exhaust to make the full system on 3"?
It would be nice in this way i could buy a 3" backbox for mine
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Old 07-26-2011, 01:25 PM   #14
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Mike, can you speak with the guys at Scorpion exhaust to make the full system on 3"?
It would be nice in this way i could buy a 3" backbox for mine
It will most likely be a full 3" system.

There is a possibility that it may be 2.75", at least for the cat-less titanium system, as this is what we did for our TTS, and the extra flow from having no cat more than makes up for the slightly smaller diameter piping, which is still bigger and provides for far more flow than the stock system.

I'll post more updates as soon as I have them.
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