1.8T SAI Resistor

This carefully chosen resistor will fool the ECU into believing you still have the secondary air injection pump connected. They are large enough to handle the full power consumed by the pump without getting hot. Simply jump the SAI pump connector on the wiring harness with this resistor and you can kiss that code goodbye! Also suitable for N118 and N249 bypass. Please choose the appropriate quantity

2.0TFSI DV Relocation Pipe

This silicone hose fits the Audi S3, SEAT Leon Cupra and Golf ED30 2.0 litre FSiT engines. It runs between the diverter valve ( located at the front of the engine) and the air intake ( rear of engine). This is available in red, blue or black.

4 Bar Fuel Pressure Regulator

The fuel pressure regulator maintains a consistent fuel pressure in the fuel lines. When a specific pressure is reached, the regulator releases excess pressure to the return system so it can be reused. A faulty fuel pressure regulator can cause low fuel pressure, high fuel pressure, rich running condition or a delay of building up pressure.

Replace your faulty regulator to keep your engine running optimally with this original Bosch part.

Rated at 4 Bar and used as an upgrade on the 1.8T platform for stage2 and stage2+

4 cylinder VW Calico coated race main bearing set

These bearings are the real deal coated bearings. Not just spray painted OEM bearings, these start as premium ACL brand race bearings. These base bearing shells feature a hardened steel backing, with increased bearing crush for better bearing shell retetion (less likely to spin). They have increased ovality to compensate for rod distortion at high rpm levels, and are designed with a high strength overlay plate for maximum fatigue resistance. All of this is covered up with a professionally applied coating by Calico, giving a truely high performance bearing from the coating all the way to the outer shell. These really are the real deal! They are available in standard or +.0005″ per shell, giving .001″ extra bearing clearance for the most extreme applications.

Fits all “modern” vw 4 cylinders. Please ask about older 1.6L and similar engines.
Standard clearance
This is for a complete set for all main caps

4 cylinder VW Calico coated race rod bearing set

These bearings are the real deal coated bearings. Not just spray painted OEM bearings, these start as premium ACL brand race bearings. These base bearing shells feature a hardened steel backing, with increased bearing crush for better bearing shell retetion (less likely to spin). They have increased ovality to compensate for rod distortion at high rpm levels, and are designed with a high strength overlay plate for maximum fatigue resistance. All of this is covered up with a professionally applied coating by Calico, giving a truely high performance bearing from the coating all the way to the outer shell. These really are the real deal! They are available in standard or +.0005″ per shell, giving .001″ extra bearing clearance for the most extreme applications.

This set is standard clearance.
This is for a complete set for all 4 rods

44mm Piston External Wastegate

Product Description

Highlights

  • Compact design for installation in even the tightest locations.
  • Fully tuneable from 4psi to 26psi spring pressure (0.28 to 1.79bar). (Tuning beyond 26psi will require a boost controller)
  • More accurate boost control with custom Eibach® springs made specifically for this application.
  • Fully serviceable with no specialist tools required.
  • Anodised billet housing.
  • Water-cooled option as standard to keep the piston, O-ring and cylinder within their optimum operating range.
  • NO Diaphragm to fail, unlike our competitors, which enables the use of high pressure compressor driven boost control above the piston if necessary or desired, without the danger of the diaphragm turning inside out
  • Unique lightweight piston design.
  • Faster response.
  • Original purchaser has “Forge Motorsport Lifetime Warranty”.
  • 304 Stainless Steel CNC machined V-band clamps supplied for easy installation and maximum clamping force.
  • 44mm industry standard weld on fittings supplied for installation to any existing 44mm set up.
  • Adjustable water inlet and outlet position.

 

Having been the world leaders in aftermarket replacement turbo actuators for the last 20 years we spent a long time conducting market research and development to find exactly what would constitute “The World’s Best External Wastegate“ and here we are… Forge Motorsport proudly present the world’s first piston wastegate with optional water cooling – the FMWCW1.

Following the release of our original piston operated wastegate we knew that we wanted to create a product that would perform to the same capability but within a more compact area.

In striving to do this, our engineers managed to develop a wastegate that exceeded all expectations.

Our new wastegate is 45% smaller than the original, and can withstand temperatures of over 1000℃ . The internals have been designed so that the piston is more responsive than ever.  It is the world’s first external, piston operated wastegate with water-cooling capability.

The Design

We observed that there were issues within the industry of external wastegates failing due to the environments they are situated in. We knew that we did not want to take a step backwards and use diaphragm internals, so we concentrated on reducing the piston and spring size.

Our engineers came up with multiple body styles and conducted flow tests on each one to determine which would perform to the best ability and still have a good aesthetic design.

The piston has a unique lightweight design and a faster response, the internal area below the piston has been minimised so that there is less area to fill/empty before boost control occurs.

 

 

Testing

Following extensive in house flow and heat tests we despatched multiple prototype wastegates to select motorsport contacts for extreme vehicle application testing.  One was even fitted to our own race Mk1 Golf.

The materials of the wastegate have been specifically chosen for their ability to withstand the harsh environment they are exposed to: The valve is made from Inconel 800 and ground with a tolerance of 30 microns (0.03mm), the guide is made from Nitronic 60 machined to the same tollerences, and the base is 304 stainless steel and the aluminium upper body is aerospace grade 6082. Even the internal O-rings are made from a special, high temperature elastomer, previously unseen in the automotive market. Nothing has been left to chance.

We sent wastegates to DubShack Racing to test on their high powered VW Lupo and Owen Developments to test on the high powered, ¼ mile drag racing Suzuki Hayabusa they had in the shop.

Owen Developments continued to test the wastegates on other turbo applications they were involved with.

 

 

With all the Engineering aspects taken care of we needed to be sure we had the best performing springs controlling this new innovative product, so rather than using a commercial spring maker we turned to the masters of spring technology ….Eibach.

Accurate turbo boost control is critical to the safe and smooth running of any forced induction engine.  There are many design elements to a Wastegate that contribute to its boost control accuracy (boost sensitivity) but perhaps none more significant than the spring.  The Wastegate spring is the component that ultimately controls the pressure at which the Wastegate valve opens and bleeds exhaust gases away from the turbo.  Eibach, as a spring manufacturer, needs no introduction, having been seen on high end motorsport and high end road cars for many decades now. They represent the ‘best’ the industry has to offer.  The Forge Motorsport engineers set out a brief to Eibach and what they proposed was nothing short of ‘best in class’ – exactly what we expected.  The springs are made from a very high strength Silicone Chrome spring steel (same as they use for F1 springs!) and most notably for this application, have a tolerance of +/-70g of force at the blow open load – that’s the equivalent force of a small confectionary bar!  So boost sensitivity, the pressure change over the target pressure that causes the valve to blow open, is now greatly enhanced and so, therefore, is the boost control.

With a combination of a single spring and shims, the following boost pressure can be accurately realised:

 

 

About Wastegates

All petrol / gasoline turbo engines utilise a wastegate of some kind and there are usually two types, an internal or external version, which refers to their location. An internal wastegate is built into the casting of the hotside of the turbo, connected to the exhaust. An external wastegate is mounted separately away from the turbo. Both these configurations provide a way to bypass the exhaust flow coming from the manifold around the turbine wheel, allowing you to maintain a set level of boost. The bypassed exhaust flow causes a reduction in the exhaust flow that is driving the turbine wheel, thus giving the ability to raise and lower boost as required to meet your target boost. Like a blow off valve, the external wastegate uses boost pressure to balance the flow bypassing the turbine.

External wastegate’s are usually used on high output engines, as it allows for a much smoother and less complicated casting on the turbo itself, as it no longer has to have provision for an internal wastegate, which in turn makes the turbo work more efficiently. Also boost creep, which is typical on a turbo with an internal wastegate where the wastegate hole is too small, is a thing of the past as the external wastegate can be of a much larger size without compromising the turbo.

9N Polo 1.8T Throttle Hose

This Silicone replacement hose fits from the throttle body to the intercooler, on the Polo 1.8 GTI or SEAT Ibiza MK4 1.8T. It can be fitted with either our front mount, or to a stock car, with the original intercooler. The re-inforced silicone structure of the hose will withstand greater temperatures and pressures than the original hose and is ideal for tuned engines.

Actuator for VAG 1.4 Twincharged Engines

This actuator is compatable with the VAG 1.4 Twincharged engines found in the Audi A1, Seat Mk5 Ibiza / Bocenegra, Skoda Fabia and Volkswagen Polo.

This product is built with a predetermined actuator spring suitable for at, or slightly above factory boost levels. The actuator can be assembled with a stiffer spring upon request. It is designed and built with the intention of increasing the boost output of a turbocharged system. We cannot guarantee compatibility with all applications, nor the ability to increase the boost output beyond a level that is within the parameters set by the engine-management-system of the given vehicle at the time of installation, whether that system is factory or aftermarket.

Actuator for VAG 2.0TSi Engines with IHI Turbo

A replacement turbo actuator for vehicles based on the MK6 Golf chassis with the 2.0 TSi engine, fitted with the IHI turbo. However, this unit will NOT work on IHI turbos that have the actuator welded to the turbine housing as well as the rod end permanently riveted to the flapper arm. This unit will only work on turbos that have the actuator bolted to the turbine housing and the removable arm. The OEM turbo/actuator will need to be inspected first to determine if this unit will work.

This actuator uses a piston design for maximum longevity in comparison to the OEM units. Using a range of available springs this actuator can be tuned to suit your requirements. This product is built with a predetermined actuator spring suitable for at, or slightly above factory boost levels. The actuator can be assembled with a stiffer spring upon request. Please contact us directly concerning this process.

Whilst this product is designed and built as a replacement part or with the intention of increasing the boost output of a turbocharged system. We cannot guarantee compatibility with all applications, nor the ability to increase the boost output beyond a level that is within the parameters set by the engine-management-system of the given vehicle at the time of installation, whether that system is factory or aftermarket. Forge Motorsport nor any of it’s authorised distributors can assume any responsibility for any adverse effects resulting from the installation and tuning of this product onto a vehicle whose engine-management-system, whether factory or aftermarket, is not capable of allowing for the desired level of adjustment. While Forge Motorsport is happy to supply you with an actuator capable of holding boost beyond that of your factory unit we are in no way capable of knowing nor suggesting that your vehicle’s engine or related systems are capable of supporting or surviving the stresses of such elevated boost pressure.

Adjustable actuator for Renault Megane 225 and RS250

Designed by Forge to replace the original component on the Renault Megane 225&RS250, this uprated actuator is serviceable and guaranteed for life. It comes with an uprated diaphragm and is machined from an aluminium billet. The mounting bracket is made from stainless steel. This product is built with a predetermined actuator spring suitable for at or slightly above factory boost levels.

The actuator can be assembled with a stiffer spring upon request. Please contact us directly concerning this process.

This product is designed and built with the intent of increasing the boost output of a turbocharged system. We cannot guarantee compatibility with all applications, nor the ability to increase the boost output beyond a level that is within the parameters set by the engine-management-system of the given vehicle at the time of installation, whether that system is factory or aftermarket. Forge Motorsport nor any of it’s Authorized Distributors can assume any responsibility for any adverse effects resulting from the installation and tuning of this product onto a vehicle whose engine-management-system, whether factory or aftermarket, is not capable of allowing for the desired level of adjustment

ARP 1.8T Main Stud Kit (06A Late 1.8t)

This is a high quality, american made main stud kit for VW/Audi 06A 1.8T engines, brought to you by ARP out of california. This is absolutely the highest quality main stud kit you can find. We are genuine ARP Distributors so buying from us gaurantees you a valid warantee. This will ensure that youre main bearings and caps stay put even under the most extreme conditions, eliminating potential bearing problems. Features High strength eliminates chances main bearing or crankshaft problems Totaly Reusable Fits late 1.8t’s like AWP, as well as all MK4 chassis 4 cylinders

ARP 12v VR6 Head Stud Kit

This is a high quality, american made head stud kit for vw 12V VR6 Engine, brought to you by ARP out of california. This is absolutely the highest quality head stud kit you can find. We are genuine ARP Distributors so buying from us gaurantees you a valid warantee. This will ensure your head does not lift even under the most extreme boost conditions and is completely reusable, great for race engines. Features High strength eliminates chances of headgasket problems Totaly Reusable ARP 204-4705

ARP 16v Head Stud Kit

This is a high quality, american made head stud kit for vw / audi 16v (9a, PL, etc) engines, brought to you by ARP out of california. This is absolutely the highest quality head stud kit you can find. We are genuine ARP Distributors so buying from us gaurantees you a valid warantee. This will ensure your head does not lift even under the most extreme boost conditions and is completely reusable, great for race engines. Features High strength eliminates chances of headgasket problems Totaly Reusable ARP 204-4204

ARP BMW E36 M50 M52 S50US S52US Head Stud Kit

ARP is the go-to manufacturer in the automotive industry for engine fasteners. Whether it be OEM replacement parts or custom hardware, their dedication to consistent top notch quality has made them a favorite in the racing world.

These ARP head studs for BMW E36 engines are made from premium grade 8740 alloy steel which is rated far superior to many “aircraft quality” competitors. The studs are heat treated to 200,000 psi then thread rolled afterward, giving them twenty times better fatigue strength over studs threaded prior to treatment (a common practice with lesser quality studs). These high-quality head studs will ensure your headgasket stays firmly planted under even the most extreme boost conditions. These parts are manufactured in the U.S.A. and are 100% re-usable.

Fits
BMW E36 Engines including M50, M52, S50US, and S52US.