Forge TIP

Jeff GTi · Post by **Jeff GTi** » Sat Jan 05, 2008 12:33 am

for those of you who have done this yourselves, as i did today, i take my hat off to you, its a quality part, providing great improvement on throttle responce and agile, smooth power delivery, but ...

... what a complete ballache to do

haha, also did the throttle body/intercooler hose too, which was much easier

jeff

KennyPOLO_Gti · Post by **KennyPOLO_Gti** » Sat Jan 05, 2008 12:20 pm

A mod am also wanting to do! Did ya take a pic by anychance of the two next to each other? Heard the standard inlet is more "collapsed" at the bend to the forge???

gti-joe · Post by **gti-joe** » Sat Jan 05, 2008 1:59 pm

Got mine in the post yesterday and was gona put them on this weekend but weather aint great up here. How did you go about it Jeff and did you need to remove anything major to get space to change the TIP. Any advice welcome.

Cheers, Joe

Jeff GTi · Post by **Jeff GTi** » Sat Jan 05, 2008 5:45 pm

strut brace, air inlet and airbox needed to be removed to gain access to it

then i went at labling it up, whats from where etc as theres loads of sensors from the standard TIP, once all were removed i got the standard plastic intake off

i then came to the metal intake to the turbo, which bolts to the face of the turbo and needed undoing and removing to expose the turbo inlet as the forge intake replaces both parts

then as im sure you will find when fitting, its awkward as hell to get the forge TIP to seat on to the turbo correctly due to the rigid black piping which it needs to tuck behind, i found some fairy liquid a god send to make things slip past each other easier here, then its just a case of putting new jubilee clips on and refitting everything, allow yourself a good half a day to do it though as it is a serious squeeze due to the sheer size of it compared to the standard

im affraid i have no pics im sorry but its massively better in terms of size and less angular than the 2 part standard jobby too, increasing airflow significantly and throttle response

from driving it, it sounds a bit more throaty again, possibly due to the bore size, i dont know but its defo there, still not chavy or over the top though, it also lets you hear the recirc valve working more as when your giving it some beans and you let off to change gear you hear almost like a boom as the air is thrown back in the intake pipe from the dv, its great

performance/power increase? maybe, i dont know but is defo an improvement to drive, but neuspeed say a gain of 5hp is achievable from just changing to their new metal intake to the turbo apposed to the standard item and keeping the standard plastic top part to the intake, and having seen theirs and the forge complete replacement, the forge item is still even larger and replaces the top plastic part, so who knows, a rr day blast will be needed for proof i think

overall, i love it and highly recommend it

gti-joe · Post by **gti-joe** » Sat Jan 05, 2008 7:15 pm

Cheers Jeff, will give it a bash the next dry, semi warmish day we have up here as dont have a garage. Is there any special tools needed or will basic tool kit sufice ?

Cheers, Joe

P.S. were the new hose clips you used the jubilee clip type or original VW
springy ones.

Jeff GTi · Post by **Jeff GTi** » Sat Jan 05, 2008 7:49 pm

not all the vw ones are big enough, so i bought jubilee clips

as for tools, i needed the following

fairy liquid - lubrication

pliers - to squeeze the standard vw clamps to remove them

ratchet to tighten the jubilee clamps (7mm socket)

flat blade screw driver - to help ease off sensors lightly and also for jubilee clips

posi drive screw driver - to remove the holding screw for the air inlet pipe from the grill, near the air box

10mm socket with extension bar - to remove the airbox retaining bolt behing the battery

allen key (unsure on size, not big though) - to remove the retaining bolt holding the metal intake on to the turbo

and as far as i can remember, thats it mate, just take your time and when you have the new TIP is finally in place, tucked behing the black rigid pipe and seated square against the turbo, assemble from the bottom up, not the other way, its most important to get the base clamped on to the turbo first before anything else, as this is the hardest part to do

but when your starting off, remove in this order

air intake

air box

engine cover (i did just so i never broke it as i had to lean over the front of the car to get my hand to the turbo

and then the sensors from nearest the top working lower, labeling up as you go, so a label for sensor 1, look where it come from and where it fits the new TIP and a label corrisponding on it, this just makes the re assembly easier

just be patient and be prepared to walk away when your stressed with it not being straight forward, i did twice, but went back to it better every time after a refreshing glass of juice and a breather

jeff

more-bhp · Post by **more-bhp** » Sat Jan 05, 2008 7:56 pm

I followed these instructions.. took 2 hours max..

http://www.ottawa-vdubbing.com/forums/p ... php?t=8651

When they say jack up car and go underneath... DO IT.. makes the job so much easier.

Has good size comparison pictures.

Have fun...

Jason

more-bhp · Post by **more-bhp** » Sat Jan 05, 2008 8:02 pm

Forgot to say...

I found a can of Stella at break time worked better than juice... lol

Jeff GTi · Post by **Jeff GTi** » Sat Jan 05, 2008 8:04 pm

thats a cool guide, and as a guide is helpful

but its for a golf, on a different layout entirely and as for cutting the clips, im not sure on that

anyway, theres a couple now for joe to go with for info, and every bit helps when going in at something you aint done before eh

andy947 · Post by **andy947** » Sat Jan 05, 2008 8:05 pm

It helps a lot if you loosen the water pipe securing bolt to give more access to fit the intake pipe to the turbo, 2 secs to remove, saves a heap of time!

Having the car jacked up to get access from below does help aswell, but not strictly required.

Cutting clips is no big deal, just make sure you use quality hose clamps which are smooth on the inside (and not a pressed thread) when replacing them.

gti-joe · Post by **gti-joe** » Sat Jan 05, 2008 8:33 pm

Cheers guys, will be giving it a go as soon as weather permits.

kc · Post by kc » Sat Jan 05, 2008 9:29 pm

well done matey for doing it yourself!

when i did mine i basically did you what you did, get it on the turbo, only to find that it wasnt on properly, then doing it all again.... then to turn around - throw a strop then try again!!

glad you like it! its a worthwhile mod!!

i put mine back on the rollers after i fitted it, it doesnt really give you much more power, but i gained about 10lbft of torque!

kc

ps - do you know what i mean now about the sound being more 'throaty'?!

Jeff GTi · Post by **Jeff GTi** » Sun Jan 06, 2008 8:32 am

kc, yeah i imagine a torque increase to be more great than a power increase, as thats how it feels, more elastic, am glad i did it, just want it back on the rolers now for another run haha

gti-joe · Post by **gti-joe** » Sun Jan 06, 2008 4:37 pm

Well did the intercooler/throttle body hose today, as you said Jeff piece of cake. Was gona attempt the TIP but was bloody frozen and started running out of light.

gti-joe · Post by **gti-joe** » Sat Jan 19, 2008 7:49 pm

Bit the bullet today and fitted the TIP. Jeff, you aint wrong what a frikin job.

Not 100% happy with the fit onto the turbo. Felt the worm drive clamp wasnt a tight enough fit as i couldnt get it positioned correctly, so used one of the VW spring clips instead. Will see how that holds.

Did you guys that have done this mod have any trouble positioning the clamp where you were confident that it was doing its job.