DIY installation of Volkswagen Racing Cold Air Intake (CAI) to suit 2011 Golf "R"

[ozmale]

Aha. Thanks Chris.
Seems like I'm not the only one concerned.
Loctite seems like a solution then.

There are lots of ways to skin a cat.

The bypass hose needs to fit over a "male" type connection. A molded silicone extension would not really work here. To be honest I prefer the supplied solution as I have seen in the past where a metal peice is molded into the silicone and in that case it always does come loose. It is not like the proper vulcanizing process to bond rubber to metal.

Chris

[ozmale]

Guys,

After years of research and thousands invested. What a load of crap. Actually it tool me about 20minutes of high school geometry and $20.

Like me a couple of guys were a bit concerned about the way the VW racing CAI kit deals with the turbo bypass hose. I gave it more thought and decided it would be a far better solution to use the existing oval shape OEM corrugated turbo inlet pipe.

After some calculations I would out that even though the pipe WA oval (ellipse) in shape I was sure a round silicone reducer could be made to fit. To use the OEM pipe I needed a silicone reducer of 80mm to 70mm.

This is exactly what was needed and is available from Melbourne $14.50 delivered.

http://www.ebay.com.au/itm/ws/eBayIS...E:L:OC:AU:1123

You also need a 90mm hose clamp about $4.

The Photos below show the DIY.
I think this is a heaps better solution than the expensive hard to fit 90 degree silicone elbow. Also it means you don't need to fiddle removing that shitty spring clip on the turbo. If this was the way the kit was designed in the first place I am sure a straight reducer is heaps cheaper than a specially made elbow plus a machined aluminum fitting.

As luck would have it the ebay reducer listed above is only 3 ply making it very flexible and easily fits over the rubber ring taking the oval shape without distortion. It is also the perfect length.



In this photo I used a 102mm hose clamp because I could not find a 90mm one but 90mm will be a perfect fit.



You can also see I have used a cable tie to stop the stainless steel spring clips from flapping round. you can remove these clips altogether but i like to be able to returns things to stock.





For an extra $20 I think this mods makes this kit heaps safer, much easier to install and all round make a much more attractive CAI.

Chris

[dave-r]

Good solution, just a shame that for the money they're charging it doesn't ship without needing someone to go all macgyver on it

[tippah]

Wow i like your imagination on this fix. Does make it look better too.

[R:.]

Good work, and fantastic write up Chris.

So far, impressions? Power, and more importantly, noise any good?

This December if you have time would love to hear this on the Nth Shore I believe you mentioned you were in Manly or something last time..

[ozmale]

Good work, and fantastic write up Chris.

So far, impressions? Power, and more importantly, noise any good?

This December if you have time would love to hear this on the Nth Shore I believe you mentioned you were in Manly or something last time..

Driving down the road with windows up you dod not hear it unless you are ginning it above 3500 then you hear a nice sucking sound.
In an enclosed space like walled driveway or under ground carpark you hear a reasonably loud deep throat ed roar.

I honestly cant say I have detected any noticeable power increase, probably need a dyno check to do that.

Yes I live at Manly anyone is welcome to visit and look at the car.

Chris

[Lucas_R]

Hi Chris - i purchased one of these VW Racing intakes a few weeks ago and im loving it. The induction/turbo sounds is sooo much better/louder (which is what i wanted to achieve). Im quite happy with the silicone pipe down to the turbo. I put locktite on the bung's thread and tightened it up super tight - its not going anywhere. I'll just make it part of my much-to-regular maintenance to make sure it isn't working its way loose - although i doubt it will.

Speaking of dyno's, i have the exact same mods as you (Bluefin and VW intake) and my car made 186.2kw a few weeks ago on a Mainline AWD dyno. After that result, i used my trusty Bluefin controller to load the stock file back on (to see the difference in power). With the stock VW file loaded back on (so stock VW file + VW intake) it make 166kw. Thought you might be interested as id assume yours is making a very similar amount of power.

[ozmale]

Hi Chris - i purchased one of these VW Racing intakes a few weeks ago and im loving it. The induction/turbo sounds is sooo much better/louder (which is what i wanted to achieve). Im quite happy with the silicone pipe down to the turbo. I put locktite on the bung's thread and tightened it up super tight - its not going anywhere. I'll just make it part of my much-to-regular maintenance to make sure it isn't working its way loose - although i doubt it will.

Speaking of dyno's, i have the exact same mods as you (Bluefin and VW intake) and my car made 186.2kw a few weeks ago on a Mainline AWD dyno. After that result, i used my trusty Bluefin controller to load the stock file back on (to see the difference in power). With the stock VW file loaded back on (so stock VW file + VW intake) it make 166kw. Thought you might be interested as id assume yours is making a very similar amount of power.

Thanks heaps for the power info, that is really worth knowing. We are told that the stock car gives 188Kw, so I am assuming we are losing 20kw through the transmission etc.

I have never Dynoed mine but when I removed my Bluefin (just to try) it felt like a lot more drop than 20kw. My car seems to go very hard, I like to tell myself I got a good one.

Chris

[Lucas_R]

No worries. Apparently most stock R's tend to put out around the 155kw mark when stock. Mine had 166kw for some reason although that figure included the VW Racing intake which would have bumped it up a few no doubt. But basically the Bluefin gives a 20kw (or thereabouts) increase at the wheels.

Thanks heaps for the power info, that is really worth knowing. We are told that the stock car gives 188Kw, so I am assuming we are losing 20kw through the transmission etc.

I have never Dynoed mine but when I removed my Bluefin (just to try) it felt like a lot more drop than 20kw. My car seems to go very hard, I like to tell myself I got a good one.

Chris

[stephen8512]

Remember, the dsg makes approx 10kw less on the dyno than the manual.