APR Presents the A4/A5/Allroad Front Mount Intercooler System!

Posted on February 2, 2016 – 5:00 pm

release-b8.5-intercooler-lg

The APR Intercooler System is a massive front mounted upgrade that dramatically reduces intake air temperature (IAT), minimizes heat soak, and provides increased performance! The system is an easy to install, direct bolt-on design, that is recommended at every stage of performance.


Quick Facts:

  • Dramatically lowers intake air temp (IAT)
    Increases horsepower while minimizing power-robbing heat soak!
    17 horsepower gain over the factory system!
  • Massive frontal surface area and core volume
    2.50″ x 5.50″ x 26.00″ – 13.75 in² frontal & 357.0 in³ volume – OEM
    2.25″ x 16.2″ x 22.00″ – 36.45 in² frontal & 801.9 in³ volume – APR
  • Highly effective core design
    Bar-and-plate core with staggered and louvered fins.
    Rigorous testing determined core style, fin density, and size.
    Low pressure drop + highly effective cooling=high performance!
  • Smooth cast end tanks
    Engineered for low turbulence/restriction and maximum flow.
    Organically shaped to promote airflow across entire core.
    Pressure tested to prevent power robbing boost leaks.
  • Easy to install
    With the bumper removed, install takes minutes!
    No trimming or drilling necessary!
    Full directions and APR world-renowned customer support included
  • Designed by engineers with lasers
    With the best equipment and smartest engineers, it just works!

Design

Unfortunately, to the untrained eye, many intercooler designs appear the same. However, effectiveness of the system and overall performance are greatly determined by several key metrics. Alloy selection, end tank design, construction type, fin style, fin density and overall core dimensions must be analyzed and balanced accordingly to deliver class-leading performance. While the OEM’s goal is to create a lightweight, easy to manufacture and inexpensive to produce, cross-platform design capable of supporting factory power levels, APR’s intercooler must be capable of supporting more than double the factory output. Achieving this goal took a multi-step approach focused around intercooler core selection, end tank design and install location.

Intercooler Core Design

The APR Intercooler core is a large bar-and-plate design featuring densely packed staggered and louvered fins. This design offers exceptional cooling while balancing pressure loss across the core, and maintaining critical airflow to the components behind the intercooler system. The core size was appropriately matched to the platform, minimizing pressure drop while leaving adequate space for appropriately designed end tanks. To APR’s mechanical engineering experts, the design represented the ultimate in performance, far exceeding the capabilities of the factory intercooler. To the driver, the result is simple: Repeatable performance, even in the most demanding of situations!

Core Style / Internal Fin Structure:

APR’s Engineers paid close attention to the balance between core effectiveness and pressure drop through the core, core style and fin density. With fin density too low, pressure drop decreases dramatically, but typically results in a core incapable of effectively cooling. Likewise, with fin density too great, pressure drop increases dramatically, resulting in the turbocharger working harder, and hotter, to produce the same level of airflow. By fine tuning this often unseen balancing act, as illustrated below, APR’s Engineers were able to maximize performance.

Internal Fin Structure

Core Size:

APR’s Engineers also paid close attention to the balancing act between core effectiveness, pressure drop and space for end tanks through core sizing. With the core too small, pressure drop decreases dramatically, but typically results in a core incapable of effectively cooling. Likewise, with core size too great, pressure drop can increase, resulting in the turbocharger working harder. However, more importantly, with no space for appropriate end tanks, utilization of the core and overall effectiveness of the system diminishes rapidly, negating the benefit of the larger core. APR’s engineers were able to balance each of these characteristics to deliver maximum performance.

The APR system increases frontal surface area by 165.09% and has a 124.31% larger core!

Intercooler End Tank Design

To fully utilize the massive core, APR’s mechanical engineers designed cast aluminum end tanks organically shaped for proper airflow distribution across the entire core. By correctly sizing the intercooler core, end tank design was not sacrificed. The one-piece end tanks are CNC machined to provide a slip resistant mounting surface for hoses, precise integrated mounting surfaces, and perfectly flat connecting surfaces used for TIG welding the tanks to the core. Through proper alignment in welding jigs, each unit is assembled to tight tolerances for a precise and accurate fit.

Intercooler Bracket Design

APR’s mechanical engineers designed CNC-bent and TIG-welded mounting brackets to securely hold the intercooler in place. The brackets make the install extremely easy. With the bumper and factory intercooler unit removed, the APR intercooler installs in minutes without any cutting, drilling or trimming. For the DIY customer, this makes a home install simple, and for everyone else it eliminates hidden costs that often come with a more labor intensive install.

Testing

Internally APR conducted a multitude of tests both on the street and on the dyno with thermocouples and pressure transducers placed at the inlet and outlet of the intercooler during the design phase. Data from these tests were used to chose the intercooler core available today. With the intercooler in it’s final production form, tests were conducted against the factory to measure the effectiveness of each system.

Testing conducted on the dyno provided a semi controlled environment for back-to-back stress testing the two systems. Utilizing a B8 A4 2.0T 6MT at APR Stage II power levels, six back-to-back twelve second dyno pulls were conducted with only 5 seconds of cool down times between runs. APR’s ECU Explorer high resolution datalogging system was used for raw sensor data collection.

The APR intercooler saw a beginning IAT of 29.25 degrees C that quickly dropped to 25.50 degrees C by the end of the first run and settled at only 34.50 degrees C by the end of the sixth run. The system effectively rejected heat soak and produced consistent dyno results. In stark contrast, the factory intercooler system did far worse. With a cooler beginning IAT of 27 degrees C, temperature rose to a staggering 42.5 degrees C after only the first run, already resulting in a poorer IAT than the APR intercooler after six back-to-back runs! As testing continued, it was clear the factory intercooler system was not built with performance in mind. IAT’s continued to rise, ending at 57.75 degrees C; an additional 23.25 degrees C higher than the APR system! This translated to a final gain of 17 AWHP over the factory intercooler by the sixth run while the power only varied by under 3 AWHP across all six runs with the APR Intercooler.

Application Guide

Audi A4 / Allroad (Typ 8K – B8 / B8.5)
Audi A5 (Typ 8T – B8 / B8.5)
Audi Q5 (Typ 8U – B8 / B8.5) – In Development

1.8 TFSI and 2.0 TFSI Engines

All Transmissions

Does not fit vehicles with the extra Audi Drive Select cooler above the factory crash bar.

Price:  $899.99

Go APR!


No Comments »

Audi TT Intercooler Upgrade

Posted on January 13, 2016 – 3:00 pm

We’ve got Candice’s APR K04 turbo kit equipped Audi TT 2.0T on our rack in “service position” with the stock intercooler out in preparation for a larger version from APR.

The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the factory intercooler system. Through a massively increased core volume, superior intercooler core design and smooth, cast end tanks, APR’s engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance. Just look at that size difference!

After we put everything back together and hand the keys back to Candice we have no doubt she’ll feel the improved throttle response the second she leaves. And her K04 turbo’d Audi TT will appreciate the cooler temperatures which will assist in maintaining good power levels as she continues on with her drive. Have fun, Candice!


No Comments »

APR Cyber Monday/Year End Sale

Posted on November 30, 2015 – 9:01 am

The APR Cyber Monday and Year End Sale is here!

APR sale pricing is good through the end of the year and consists of the following:

  • APR ECU Upgrade Sale: 10% off retail!
  • APR TCU Upgrade Sale: 10% off retail!

No appointments necessary! Roll through between 9am and 4pm, Monday through Friday. Contact the Achtuning sales team with any questions by calling 425-895-0000 or email sales@achtuning.com! #GoAPR


No Comments »

APR Turbocharger Upgrade Loyalty Program

Posted on September 28, 2015 – 12:12 pm

Achtuning is pleased to announce the APR turbocharger upgrade path just got a little easier for our loyal APR customers.  Starting today, if you’ve purchased an APR ECU Upgrade and want to upgrade to one of APR’s Stage III or K04 turbocharger systems on FSI, TSI and TFSI engines, you can take advantage of fantastic savings!  APR has also lowered their standard pricing on select systems as well.  It’s their way of saying “thank you” for enjoying their ECU Upgrades before stepping up to the big leagues!

To see the savings, head on over to our product pages and take a look at the new pricing tiers.  APR customers can take $300 off K04 Turbocharger Systems, and $500 off Stage III Turbocharger Systems!  Additionally, APR’s $149 “fully loaded” EMCS Program Switching can be added for free!

APR’s new loyalty pricing is as follows:

  • $2,299.99 – Save $300! – APR K04 Turbo System (Trans EA113/EA888 Gen 2)
  • $2,399.99 – Save $300! – APR K04 Turbo System w/ 3Bar Map (Trans EA888 Gen 1)
  • $2,999.99 – Save $300! – APR K04 Turbo System (B7/B8/B8.5 A4/A5)
  • $4,999.99 – Save $500! – APR Stage III GTX2867R Turbo System (EA888 Gen 1)
  • $5,999.99 – Save $500! – APR Stage III GTX2867R Turbo System (EA113)
  • $9,499.99 – Save $500! – APR Stage III GTX3576R Turbo System (TT RS)
  • Free – Save $149 – APR “Fully Loaded” EMCS Program Switching Upgrade

No Comments »

APR Sale: Now through October 9th

Posted on September 28, 2015 – 11:12 am

APR hardware & software is on sale now through October 9th!

For more than a decade, APR has been proud to be the title sponsor of H2O International.  Supporting this fun and exciting event has given them an excellent excuse to travel to Ocean City Maryland each year to visit their customers and the community while also offering exciting savings on APR products, which we are happy to pass on to you here at Achtuning!

APR sale pricing is available now through October 9th and consists of the following:

– APR ECU Upgrade Sale: 10% off retail!
– APR TCU Upgrade Sale: 10% off retail!
– APR Hardware Sale: 10% off retail on select items!
– APR Turbo Loyalty Program: New retail pricing, plus an additional $300-500 with free EMCS program switching for existing APR Customers!  Learn more about APR’s new Turbo Loyalty Program in an upcoming blog post!

 

Continue to shop online for all your APR needs with sale pricing automatically applied.  For ECU and TCU software upgrades, no appointment is necessary!  Just roll through between the hours of 9am and 4pm, Monday through Friday!!  Combine your APR sale pricing with a purchase of an intake and get FREE INSTALL!!


No Comments »

APR Sale – July 7th to July 31st!

Posted on July 7, 2015 – 10:00 am

APR is offering sale pricing now through July 31st on some of their most popular performance upgrades, available and IN STOCK right here at Achtuning!

APR EMCS Program Switching Sale: Fully loaded ECU’s are an additional $149 over the standard ECU price! On available ECUs, add up to 4 Program Modes: Stock, APR octane specific performance modes, and APR valet mode. Add APR Mobile on compatible platforms and enjoy switching from your phone or tablet!

APR TT RS Stage 3 GTX Turbocharger System Sale: Save $3000 off the APR 2.5 TFSI Stage 3 GTX Turbocharger System and have up to 665 horsepower on your Audi TT RS!

APR 2.0T K04 Turbocharger Sale: Save $250 off the APR 2.0 TSI K04 Turbocharger System and enjoy up to 375 horsepower and over 400 ft-lbs of torque!

APR 2.0T HPFP Sale: Save $100 off new and rebuilt APR HPFPs, a necessary upgrade for FSI vehicles to experience Stage 1+, 2+, K04, Stage 3 and 3+ power level!

APR Shifter Cable Bracket Sale: Save $50 off APR Shifter Cable Brackets and enjoy smooth and crisp shifts without the slop associated with the factory plastic and rubber grommet unit.

APR 2.0T Runner Flap Delete Sale: Save $50 off APR Runner Flap Delete and free up some horsepower on your FSI platform vehicle!


No Comments »

APR Cast Downpipe Exhaust System for the 2.5 TFSI TTRS and RS3!

Posted on May 7, 2015 – 9:00 am

APR is pleased to present the ultimate cast downpipe exhaust system for the 2.5 TFSI Audi TTRS and RS3! Upgrading the restrictive factory downpipe with the APR Cast Downpipe is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gases at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.

Quick facts:

  • * Designed and assembled in-house.
  • * T304L stainless steel construction.
  • * Argon back-purged TIG welding.
  • * Investment cast downpipe.
  • * 119mm bellmouth inlet with integrated flange.
  • * Low profile, sealed/corrugated flex section.
  • * 76mm outlet with integrated bracket.
  • * 8mm billet bracket.
  • * 76mm brushed and de-burred piping.
  • * Non-swedged/slip-fit/flanged piping.
  • * Investment cast o2 bungs with billet plugs.
  • * 300 cell, 100mm x 100mm GESI catalyst.
  • * OEM-style slip-on clamps.
  • * Split reducer for OEM catback compatibility.
  • * APR Stage II ECU Upgrade price waived.
  • * Limited lifetime warranty.
  • Application Guide.
    Vehicles
    Audi RS3 (8V/MKIII) and Audi TTRS (8N/MKII)

    Engine
    2.5TFSI

    Transmission
    All

    Drivetrain
    All Wheel Drive

    Part Number
    DPK0006
    Universal 76mm Catback Fit Kit.
    Description
    Universal Fit kit

    Part Number
    FIT0001
    APR’s cast downpipe exhaust system mates perfectly to the factory catback exhaust system with the included reducer. For compatibility with most 76mm catback exhaust systems, a 76mm link pipe must be installed between the downpipe and catback. APR’s universal fit kit includes a 200mm link pipe and clamp that can be cut to length for compatibility across a wide range of systems.


    No Comments »

    APR S6 & S7 4.0T ECU v1.1

    Posted on April 2, 2015 – 10:00 am

    Version 1.1 is now available for the S6 and S7 4.0 TFSI offering more power and torque, as well as a smoother, more refined, driving experience.  APR’s engineers have unlocked 627 ft-lbs of torque and 563 horsepower with this new Stage I ECU Upgrade with as much as 187 ft-lbs and 125 horsepower over stock on 93 octane!  Those looking for even more power can use the 100 octane race fuel mode to boost output to 635 ft-lbs and 578 horsepower!  Roll through between 9am and 4pm, Monday through Friday.  No appointments necessary!

     

     


    No Comments »

    Audi (B8) A4 APR Software Update!

    Posted on February 27, 2015 – 9:00 am

    With over half a decade of development poured into this platform, APR’s Engineers are pleased to deliver several free upgrades to our existing customers. APR Stage I, Stage II and their K04 Turbocharger ECU upgrades are now revised with APR’s new calibration strategies designed to produce a fantastic driving experience with more power and torque on tap!

    APR’s calibration experts spent months working with the various ECU, hardware and octane configurations to deliver a driving experience second to none. Major improvements were made to the way the throttle behaves, leaving the driver to feel more connected to the vehicle than ever before. With control and response maximized, APR’s engineers set out to increase power while keeping factory comforts in mind during part throttle driving. Engine load, valve lift, cam phasing and boost levels were all optimized to ensure the engine was breathing as freely as possible for maximum output. Ignition, lambda and other aspects of the direct injection fueling system were tweaked to raise and refine power further. The end result is a fantastic leap in performance and response that wakes up the engine sooner in the RPM band and carries horsepower and torque further towards redline.

    Please visit each product page for full details, including our performance charts at the wheels, crank and the gain over stock using 91, 93 and 100 octanes!

    New Figures:

    Stage I ECU Upgrade | Product Page:

    • 301 FT-LBS / 256 HP – max gain of + 53 FT-LBS / + 55 HP over stock on 91.
    • 322 FT-LBS / 266 HP – max gain of + 74 FT-LBS / + 66 HP over stock on 93.
    • 323 FT-LBS / 282 HP – max gain of + 74 FT-LBS / + 76 HP over Stock on 100.

    Stage I v1.3 vs v2.0, at all four wheels

    Stage II ECU Upgrade | Product Page:

    • 341 FT-LBS / 287 HP – max gain of + 92 FT-LBS / + 97 HP over stock on 91.
    • 354 FT-LBS / 291 HP – max gain of +105 FT-LBS / +101 HP over stock on 93.
    • 359 FT-LBS / 304 HP – max gain of +109 FT-LBS / +111 HP over stock on 100.

    Stage II v1.3 vs v2.0, at all four wheels

    K04 Turbo Upgrade | Product Page:

    • 321 FT-LBS / 339 HP – max gain of +121 FT-LBS / +149 HP over stock on 91.
    • 342 FT-LBS / 348 HP – max gain of +130 FT-LBS / +158 HP over stock on 93.
    • 387 FT-LBS / 363 HP – max gain of +145 FT-LBS / +171 HP over stock on 100.

    K04 Turbocharger v2.0 vs v3.0, at all four wheels

    APR’s Stage 1 and Stage 2 ECU Upgrades are now version 2.0 while the K04 upgrade is version 3.0. No appointment necessary, just roll through between 9am and 4pm, Monday through Friday!


    No Comments »

    APR Rolling Out New Products!

    Posted on February 25, 2015 – 10:00 am

    APR is changing up their game in a big way and we are starting to see the fruits of their labor as  fresh new product is coming down the pipeline.  As always, our commitment to offering and STOCKING your APR performance upgrades means we will be one of the first distributors to receive them so you can walk out the door with parts in hand or simply arrange a time for install.  “Go APR” at Achtuning!

    APR Presents the 1.8T/2.0T EA888 Gen 3 Boost Tap – v2!

    The APR Boost Tap for the 1.8T and 2.0T EA888 Gen 3 engines is a simple, yet elegant solution for referencing boost pressure and vacuum as is commonly necessary for boost gauges. The boost tap plugs into an unused port on the factory intake manifold and doesn’t interfere with the factory T-MAP sensor.

     

     

    Traditionally boost is tapped by spacing out the factory T-MAP sensor on top of the intake manifold. However, APR’s engineers discovered using this location lead to inconsistencies in intake air temperature readings and potentially a loss of power. Upon this discovery, APR’s engineering team went back to the drawing board and came up with a new and unique solution.

     

    Kit Includes:

    • 1 Billet boost tap
    • 2 Viton o-ring seals
    • 1 Stainless steel barbed connection point
    • 1 Brass “No-buzz” mechanical boost gauge restrictor pill
    • 1 Tap cap
    • 5 Stepless OEM style ear clamps
    • 96 Inches of 200 PSI hose
    • 1 T-fitting
    • 5 Black cable ties
    • 1 Bag of anti-sieze
    • 1 Tapping tool

     

    Utilizing the included punch tool on a warm engine, a boost and vacuum reference port is easily spread opened on the factory intake manifold. The billet aluminum boost tap then connects to the port and uses dual Viton o-ring seals for leak free operation. The reference hoses connect to the rear of the tap via a barbed stainless steel connection point and conveniently routes through the engine bay.

    In addition to the boost tap, APR provides several extra components to help suit each individual’s needs. For those requiring more than one reference source, a T-fitting allows for more tapping points. In the case where a mechanical boost gauge is used, the brass restrictor pill limits flow and cures gauge buzz. Just less than 100 inches of 200 PSI hose is included with OEM style ear clamps and black cable ties to allow for neatly routing hose through the engine bay.


    Application Guide

    All 1.8T and 2.0T EA888 Gen 3 Engines

    Part Number

    MS100101

    Price

    $59.99

    FREE UPGRADE NOTE:

    Customers who have purchased APR’s previous MS100079 boost tap are entitled to upgrade to the new, better designed, boost tap for free. The customer will only be responsible for installation costs.

     

    APR Presents the 1.8/2.0T EA888 Gen 3 Cast Downpipe Exhaust System!

     

    Upgrading the restrictive factory downpipe with the APR Cast Downpipe Exhaust System is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gasses at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.


     

    Quick facts:

    • Designed and assembled in-house.
    • T304L stainless steel construction.
    • Argon back-purged TIG welding.
    • Investment cast downpipe.
    • 77mm inlet with integrated flange.
    • Low profile, sealed/corrugated flex section.
    • 76mm outlet with integrated bracket.
    • 8mm billet bracket.
    • 76mm brushed and de-burred piping.
    • Non-swedged/slip-fit/flanged piping.
    • Investment cast o2 bung.
    • 300 cell, 100mm x 100mm GESI catalyst.
    • OEM-style slip-on clamps.
    • Reducer for OEM catback compatibility.
    • APR Stage II ECU Upgrade price waived.
    • Limited lifetime warranty.

    The factory downpipe system consists of smaller, 63mm piping with varying bends and multiple restrictive high-cell-count catalysts, all of which contribute to a less than ideal flow path and hindered performance. APR’s engineers took a multi-step approach to maximizing flow, reducing under hood temperature, and eliminating unnecessary restrictions all in a unique package only APR can deliver.

    Detailed component photos and information

    The APR Cast Downpipe Exhaust System is a complex system designed to deliver maximum performance. Each component was designed and developed with the absolute best in performance, strength, reliability and quality in mind.

    Cast Downpipe Inlet and Outlet

    The exhaust system features a strong, investment cast, T304L inlet and outlet designed to maximize flow and minimize turbulence. By casting the inlet, APR’s engineers were able to create a smooth and high-flow exhaust path that maximized flow through swept blends and shapes that are otherwise not possible through conventional fabrication techniques. The inlet perfectly matches the factory turbocharger’s 77mm outlet and gradually necks down over a long distance to further enhance performance. The mounting flange and bracket are integrated into the casting, and TIG welding at the flex section ensures a clean inner surface eliminating turbulence, vortices and eddies to the highest degree.

    With a nominal wall thickness of 2.55mm the downpipe is strong and produces a refined exhaust note compared to thin wall tubing systems. The cast sections undergo a tumbling process to smooth and de-burr any imperfections inside the pipe, while simultaneously enhancing the exterior finish. Lastly, all necessary surfaces are CNC machined for an accurate fit.

    Flex Section

    APR’s engineers specified a T304L stainless steel, OEM-style flex section that is fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time.

    Bracket

    Designed to stand the test of time, the bracket is CNC machined from 8mm-thick billet T304L stainless steel and the hanger feet are threaded into place, eliminating the need for welds. Weight is removed from the bracket, wherever possible, while not hindering its structural integrity. The bracket attaches to the cast downpipe’s integrated mounting bracket, and CNC machined spacers enable compatibility across multiple vehicles.

    Piping

    The APR Downpipe Exhaust System features premium grade T304L stainless steel for its excellent appearance, strength and corrosion resistance properties. The pipe is rolled to the 76mm European standard diameter with a 1.5mm wall thickness and a seemingly non-existent weld seam.

    Pipe is cut to length in-house via APR’s CNC-controlled bandsaw to an accuracy of .25mm, ensuring a precise fit. Each pipe is de-burred, and the exterior finish is brushed to give the exhaust piping a clean and attractive appearance worthy of the APR name. APR’s fabrication team uses argon back-purging during the welding process, leaving a clean and smooth interior surface, and TIG welding for strength and appearance. Lastly, no swedging or slip-fitting is necessary due to APR’s OEM-style clamp design, leaving smooth and less turbulent connection points.

    Clamps

    APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.

    O2 Sensor Bung

    APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bung. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean.

    Catalyst

    APR’s engineers specified a high-quality and high-flow GESI metal 300-cell catalyst ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.

    Internally the catalytic converter features a proprietary blend of precious metals and loading technology that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalyst is placed far away from the turbo outlet to reduce turbulence in the downpipe and to help reduce under-hood temperature. The low-profile catalyst features a fully captured substrate brick, which is furnace braised to the outer mantle and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalyst is a reduction in noise, making the system as a whole more pleasing to the ear.

    Reducer

    A simple and removable, T304L stainless steel reducer, featuring a smooth transition, is included, making the APR Cast Downpipe Exhaust System directly compatible with the OEM catback exhaust system.

    Oxygen Sensor Harness

    A high quality oxygen sensor extension harness is included as the catalyst and sensor bung is relocated further away from the turbocharger.

    Dyno Testing

    1.8T

    Wheel Graph | Gain Over Stock Graph

    2.0T

    Wheel Graph | Gain Over Stock Graph

    Reported wheel figures measured on APR’s in house Dynapack Dynamometer with a 2014 MK7 Golf Tiptronic and 2014 MK7 GTI DSG, using SAEJ1349 correction and an average of multiple runs. Crank figures estimated based on the measured wheel figures. Results will vary depending upon environmental conditions, vehicle, transmission, vehicle health, operating conditions, temperatures, fuel grade, dyno type, dyno setup, and other modifications.

     

    Application Guide

    Vehicles

    • Audi A3 (8V / MKIII)
    • Seat Leon / Cupra / Cupra R (MKII)
    • Skoda Octavia / VRS (MKIII)
    • Volkswagen Golf / GTI (MKVII)
    • Passat (B9)

    Engines

    • 1.8T EA888 Gen 3
    • 2.0T EA888 Gen 3 (IS20 Turbo / Low output engines)
    • 2.0T EA888 Gen 3 (IS38 Turbo / High output engines)

    Drivetrain

    • Front Wheel Drive

    Transmissions

    • 5 & 6 Speed Manual
    • Tiptronic
    • DSG / Stronic 6 & 7 Speed

    Part Number and Price

    DPK0004 – $749.49

    Stage II ECU Upgrade Information

    For the best results, APR recommends installing the Stage II ECU Upgrade. This upgrade requires purchase of an APR Stage I ECU Upgrade, and is included for free to the original owner and original vehicle with the purchase of an APR Cast Downpipe Exhaust System!

    Stage II Upgrade Pricing

    • 1.8T EA888 Gen 3 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA888 Gen 3 (IS20 Turbo / Low output engines) – Front Wheel Drive – Retail: $174.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA888 Gen 3 (IS38 Turbo / High output engines) – Front Wheel Drive – Retail: $199.00 | Price with Purchase of APR Downpipe: Free

     

     

    APR Presents the 1.8/2.0T EA113/EA888 Gen 1 Cast Downpipe Exhaust System!

     

    Upgrading the restrictive factory downpipe with the APR Cast Downpipe Exhaust System is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gasses at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.

    Quick facts:

    • Designed and assembled in-house.
    • T304L stainless steel construction.
    • Argon back-purged TIG welding.
    • Investment cast downpipe.
    • 80mm inlet with integrated o2 bung and flange.
    • Low profile, sealed/corrugated flex section.
    • 76mm outlet with integrated bracket.
    • 8mm billet bracket.
    • 76mm brushed and de-burred piping.
    • Non-swedged/slip-fit/flanged piping.
    • Investment cast o2 bungs with billet plugs.
    • 300 cell, 100mm x 100mm GESI catalyst.
    • OEM-style slip-on clamps.
    • Reducer for OEM catback compatibility.
    • OEM gasket.
    • APR Stage II ECU Upgrade price waived.
    • Limited lifetime warranty.

    Detailed component photos and information

    The APR Cast Downpipe Exhaust System is a complex system designed to deliver maximum performance. Each component was designed and developed with the absolute best in performance, strength, reliability and quality in mind.

    Cast Downpipe Inlet and Outlet

    The exhaust system features a strong, investment cast, T304L inlet and outlet designed to maximized flow and minimize turbulence. By casting the inlet, APR’s engineers were able to create a smooth and high-flow exhaust path that maximized flow through swept blends and shapes that are otherwise not possible through conventional fabrication techniques. The inlet perfectly matches the factory turbocharger’s 80mm outlet and gradually necks down over a long distance to further enhance performance. The mounting flange, oxygen sensor bung and bracket are integrated into the casting, and TIG welding at the flex section ensures a clean inner surface eliminating turbulence, vortices and eddies to the highest degree.

    With a nominal wall thickness of 2.55mm the downpipe is strong and produces a refined exhaust note compared to thin wall tubing systems. The cast sections undergo a tumbling process to smooth and de-burr any imperfections inside the pipe, while simultaneously enhancing the exterior finish. Lastly, all necessary surfaces are CNC machined for an accurate fit.

    Flex Section

    APR’s engineers specified a T304L stainless steel, OEM-style flex section that is fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time.

    Bracket

    Designed to stand the test of time, the bracket is CNC machined from 8mm-thick billet T304L stainless steel and the hanger feet are threaded into place, eliminating the need for welds. Weight is removed from the bracket, wherever possible, while not hindering its structural integrity. The bracket attaches to the cast downpipe’s integrated mounting bracket, and CNC machined spacers enable compatibility across multiple vehicles.

    Piping

    The APR Downpipe Exhaust System features premium grade T304L stainless steel for its excellent appearance, strength and corrosion resistance properties. The pipe is rolled to the 76mm European standard diameter with a 1.5mm wall thickness and a seemingly non-existent weld seam.

    Pipe is cut to length in-house via APR’s CNC-controlled bandsaw to an accuracy of .25mm, ensuring a precise fit. Each pipe is de-burred, and the exterior finish is brushed to give the exhaust piping a clean and attractive appearance worthy of the APR name. APR’s fabrication team uses argon back-purging during the welding process, leaving a clean and smooth interior surface, and TIG welding for strength and appearance. Lastly, no swedging or slip-fitting is necessary due to APR’s OEM-style clamp design, leaving smooth and less turbulent connection points.

    Clamps

    APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.

    O2 Sensor Bungs

    APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bungs. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean. Lastly, a billet T304L stainless steel bung plug is included to cap off extra ports not needed on some models.

    Catalyst

    APR’s engineers specified a high-quality and high-flow GESI metal 300-cell catalyst ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.

    Internally the catalytic converter features a proprietary blend of precious metals and loading technology that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalyst is placed far away from the turbo outlet to reduce turbulence in the downpipe and to help reduce under-hood temperature. The low-profile catalyst features a fully captured substrate brick, which is furnace braised to the outer mantle and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalyst is a reduction in noise, making the system as a whole more pleasing to the ear.

    Reducer

    A simple and removable, T304L stainless steel reducer, featuring a smooth transition, is included, making the APR Cast Downpipe Exhaust System directly compatible with the OEM catback exhaust system.

    Gasket

    Included with each system is an OEM gasket, designed to mate between the downpipe and the turbocharger.

    Application Guide

    Vehicles

    • Audi A3 (MKII / 8P)
    • Seat Altea (5P)
    • Seat Leon / Cupra / Cupra R (1P / MKII)
    • Seat Toledo (5P / MKIII)
    • Skoda Octavia / VRS (MKII)
    • Skoda Superb (MKII / T3)
    • Volkswagen Beetle (MKII)
    • Volkswagen CC
    • Volkswagen Eos
    • Volkswagen Golf / GTI / ED30 / ED35 / Pirelli (MK5 / MK6)
    • Volkswagen Jetta / GLI (MK5 / MK6)
    • Volkswagen Passat (B7)
    • Volkswagen Scirocco / Scirocco R (MKIII)

    Engines

    • 1.8T EA888 Gen 1
    • 2.0T EA113 (K03)
    • 2.0T EA113 (K04)
    • 2.0T EA888 Gen 1

    Drivetrain

    • Front Wheel Drive

    Transmissions

    • 6 Speed Manual
    • Tiptronic
    • DSG

    Part Number and Price

    DPK0002 – $749.99

    Stage II ECU Upgrade Information

    For the best results, APR recommends installing the Stage II ECU Upgrade. This upgrade requires purchase of an APR Stage I ECU Upgrade, and is included for free to the original owner and original vehicle with the purchase of an APR Cast Downpipe Exhaust System!

    Stage II Upgrade Pricing

    • 1.8T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA113 (K03) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA113 (K04) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free

     

    APR Presents the 1.8/2.0T EA113/EA888 Gen 1 AWD Cast Downpipe Exhaust System!

    Upgrading the restrictive factory downpipe with the APR Cast Downpipe Exhaust System is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gasses at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.

    Quick facts:

    • Designed and assembled in-house.
    • T304L stainless steel construction.
    • Argon back-purged TIG welding.
    • Investment cast downpipe.
    • 80mm inlet with integrated o2 bung and flange.
    • Low profile, sealed/corrugated flex section.
    • 76mm outlet with integrated bracket.
    • 8mm billet bracket.
    • 76mm brushed and de-burred piping.
    • Non-swedged/slip-fit/flanged piping.
    • Investment cast o2 bungs with billet plugs.
    • 300 cell, 100mm x 100mm GESI catalyst.
    • OEM-style slip-on clamps.
    • Low-profile, broadband noise cancellation resonator.
    • Reducer for OEM catback compatibility.
    • OEM gasket.
    • APR Stage II ECU Upgrade price waived.
    • Limited lifetime warranty.

    Detailed component photos and information
    The APR Cast Downpipe Exhaust System is a complex system designed to deliver maximum performance. Each component was designed and developed with the absolute best in performance, strength, reliability and quality in mind.

    Cast Downpipe Inlet and Outlet

    The exhaust system features a strong, investment cast, T304L inlet and outlet designed to maximized flow and minimize turbulence. By casting the inlet, APR’s engineers were able to create a smooth and high-flow exhaust path that maximized flow through swept blends and shapes that are otherwise not possible through conventional fabrication techniques. The inlet perfectly matches the factory turbocharger’s 80mm outlet and gradually necks down over a long distance to further enhance performance. The mounting flange, oxygen sensor bung and bracket are integrated into the casting, and TIG welding at the flex sectionensures a clean inner surface eliminating turbulence, vortices and eddies to the highest degree.

    With a nominal wall thickness of 2.55mm the downpipe is strong and produces a refined exhaust note compared to thin wall tubing systems. The cast sections undergo a tumbling process to smooth and de-burr any imperfections inside the pipe, while simultaneously enhancing the exterior finish. Lastly, all necessary surfaces are CNC machined for an accurate fit.

    Flex Section

    APR’s engineers specified a T304L stainless steel, OEM-style flex section that is fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time.

    Bracket

    Designed to stand the test of time, the bracket is CNC machined from 8mm-thick billet T304L stainless steel and the hanger feet are threaded into place, eliminating the need for welds. Weight is removed from the bracket, wherever possible, while not hindering its structural integrity. The bracket attaches to the cast downpipe’s integrated mounting bracket, and CNC machined spacers enable compatibility across multiple vehicles.

    Piping

    The APR Downpipe Exhaust System features premium grade T304L stainless steel for its excellent appearance, strength and corrosion resistance properties. The pipe is rolled to the 76mm European standard diameter with a 1.5mm wall thickness and a seemingly non-existent weld seam.

    Pipe is cut to length in-house via APR’s CNC-controlled bandsaw to an accuracy of .25mm, ensuring a precise fit. Each pipe is de-burred, and the exterior finish is brushed to give the exhaust piping a clean and attractive appearance worthy of the APR name. APR’s fabrication team uses argon back-purging during the welding process, leaving a clean and smooth interior surface, and TIG welding for strength and appearance. CNC mandrel bending is used to ensure a continuous diameter throughout the design. Lastly, no swedging or slip-fitting is necessary due to APR’s OEM-style clamp design, leaving smooth and less turbulent connection points.

    Clamps

    APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.

    O2 Sensor Bungs

    APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bungs. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean. Lastly, a billet T304L stainless steel bung plug is included to cap off extra ports not needed on some models.

    Catalyst

    APR’s engineers specified a high-quality and high-flow GESI metal 300-cell catalyst ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.

    Internally the catalytic converter features a proprietary blend of precious metals and loading technology that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalyst is placed far away from the turbo outlet to reduce turbulence in the downpipe and to help reduce under-hood temperature. The low-profile catalyst features a fully captured substrate brick, which is furnace braised to the outer mantle and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalyst is a reduction in noise, making the system as a whole more pleasing to the ear.

    Resonator

    A broadband noise cancellation resonator is used to reduce the volume of the exhaust note. The low profile T304L stainless steel cylinder features a straight perforated tube, wrapped in T3 long-strand stainless steel fiber followed by a tightly woven fiberglass outer wrap. The straight-through design keeps exhaust velocity high, and turbulence low maximizing performance. A brushed finish is applied to the exterior to give the resonator an attractive appearance.

    Reducer

    A simple and removable, T304L stainless steel reducer, featuring a smooth transition, is included, making the APR Cast Downpipe Exhaust System directly compatible with the OEM catback exhaust system.

    Gasket

    Included with each system is an OEM gasket, designed to mate between the downpipe and the turbocharger.

    Application Guide

    Vehicles

    • Audi A3 / S3 (MKII / 8P)
    • Volkswagen Golf / Golf R (MK5 / MK6)

    Engines

    • 1.8T EA888 Gen 1
    • 2.0T EA113 (K03)
    • 2.0T EA113 (K04)
    • 2.0T EA888 Gen 1

    Drivetrain

    • All Wheel Drive

    Transmissions

    • 6 Speed Manual
    • DSG

    Part Number and Price

    DPK0001 – $899.99

    Stage II ECU Upgrade Information

    For the best results, APR recommends installing the Stage II ECU Upgrade. This upgrade requires purchase of an APR Stage I ECU Upgrade, and is included for free to the original owner and original vehicle with the purchase of an APR Cast Downpipe Exhaust System!

    Stage II Upgrade Pricing

    • 1.8T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA113 (K03) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA113 (K04) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free

     

    APR Presents the 1.8/2.0T EA888 Gen 3 Cast Downpipe Exhaust System! (NON-MQB)

     

     

    Upgrading the restrictive factory downpipe with the APR Cast Downpipe Exhaust System is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gasses at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.

    Quick facts:

    • Designed and assembled in-house.
    • T304L stainless steel construction.
    • Argon back-purged TIG welding.
    • Investment cast downpipe.
    • 77mm inlet with integrated flange.
    • Low profile, sealed/corrugated flex section.
    • 76mm outlet with integrated bracket.
    • 8mm billet bracket.
    • 76mm brushed and de-burred piping.
    • Non-swedged/slip-fit/flanged piping.
    • Investment cast o2 bungs with billet plugs.
    • 300 cell, 100mm x 100mm GESI catalyst.
    • OEM-style slip-on clamps.
    • Reducer for OEM catback compatibility.
    • APR Stage II ECU Upgrade price waived.
    • Limited lifetime warranty.

    The factory downpipe system consists of smaller, 63mm piping with varying bends and multiple restrictive high-cell-count catalysts, all of which contribute to a less than ideal flow path and hindered performance. APR’s engineers took a multi-step approach to maximizing flow, reducing under hood temperature, and eliminating unnecessary restrictions all in a unique package only APR can deliver.

    Detailed component photos and information

    The APR Cast Downpipe Exhaust System is a complex system designed to deliver maximum performance. Each component was designed and developed with the absolute best in performance, strength, reliability and quality in mind.

    Cast Downpipe Inlet and Outlet

    The exhaust system features a strong, investment cast, T304L inlet and outlet designed to maximized flow and minimize turbulence. By casting the inlet, APR’s engineers were able to create a smooth and high-flow exhaust path that maximizes flow through swept blends and shapes that are otherwise not possible through conventional fabrication techniques. The inlet perfectly matches the factory turbocharger’s 77mm outlet and gradually necks down over a long distance to further enhance performance. The mounting flange and bracket are integrated into the casting, and TIG welding at the flex section ensures a clean inner surface eliminating turbulence, vortices and eddies to the highest degree.

    With a nominal wall thickness of 2.55mm the downpipe is strong and produces a refined exhaust note compared to thin wall tubing systems. The cast sections undergo a tumbling process to smooth and de-burr any imperfections inside the pipe, while simultaneously enhancing the exterior finish. Lastly, all necessary surfaces are CNC machined for an accurate fit.

    Flex Section

    APR’s engineers specified a T304L stainless steel, OEM-style flex section that is fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time.

    Bracket

    Designed to stand the test of time, the bracket is CNC machined from 8mm-thick billet T304L stainless steel and the hanger feet are threaded into place, eliminating the need for welds. Weight is removed from the bracket, wherever possible, while not hindering its structural integrity. The bracket attaches to the cast downpipe’s integrated mounting bracket, and CNC machined spacers enable compatibility across multiple vehicles.

    Piping

    The APR Downpipe Exhaust System features premium grade T304L stainless steel for its excellent appearance, strength and corrosion resistance properties. The pipe is rolled to the 76mm European standard diameter with a 1.5mm wall thickness and a seemingly non-existent weld seam.

    Pipe is cut to length in-house via APR’s CNC-controlled bandsaw to an accuracy of .25mm, ensuring a precise fit. Each pipe is de-burred, and the exterior finish is brushed to give the exhaust piping a clean and attractive appearance worthy of the APR name. APR’s fabrication team uses argon back-purging during the welding process, leaving a clean and smooth interior surface, and TIG welding for strength and appearance. Lastly, no swedging or slip-fitting is necessary due to APR’s OEM-style clamp design, leaving smooth and less turbulent connection points.

    Clamps

    APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.

    O2 Sensor Bungs

    APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bungs. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean. Lastly, a billet T304L stainless steel bung plug is included to cap off extra ports not needed on some models.

    Catalyst

    APR’s engineers specified a high-quality and high-flow GESI metal 300-cell catalyst ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.

    Internally the catalytic converter features a proprietary blend of precious metals and loading technology that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalyst is placed far away from the turbo outlet to reduce turbulence in the downpipe and to help reduce under-hood temperature. The low-profile catalyst features a fully captured substrate brick, which is furnace braised to the outer mantle and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalyst is a reduction in noise, making the system as a whole more pleasing to the ear.

    Reducer

    A simple and removable, T304L stainless steel reducer, featuring a smooth transition, is included, making the APR Cast Downpipe Exhaust System directly compatible with the OEM catback exhaust system.

    Dyno Testing

    Wheel Figures | Gain over Stock

    Reported wheel figures measured on APR’s in house Dynapack Dynamometer with a 2013.5 Jetta GLI 6-speed manual, using SAEJ1349 correction and an average of multiple runs. Crank figures estimated based on the measured wheel figures. Results will vary depending upon environmental conditions, vehicle, transmission, vehicle health, operating conditions, temperatures, fuel grade, dyno type, dyno setup, and other modifications.

    Application Guide

    Vehicles

    • Volkswagen Beetle (MKII)
    • Volkswagen Eos
    • Volkswagen Jetta / GLI (MK6)
    • Volkswagen Scirocco (MKIII)
    • Volkswagen Passat (B7)

    Engines

    • 1.8 TSI EA888 Gen 3
    • 2.0 TSI EA888 Gen 3

    Drivetrain

    • Front Wheel Drive

    Transmissions

    • 5 Speed Manual
    • 6 Speed Manual
    • Tiptronic
    • DSG

    Part Number and Price

    DPK0007 – $749.99

    Stage II ECU Upgrade Information

    For the best results, APR recommends installing the Stage II ECU Upgrade. This upgrade requires purchase of an APR Stage I ECU Upgrade, and is included for free to the original owner and original vehicle with the purchase of an APR Cast Downpipe Exhaust System!

    Stage II Upgrade Pricing

    • 1.8 TSI EA888 Gen 3 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
    • 2.0 TSI EA888 Gen 3 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free

    The APR Difference:

    The Engineering and Designing Phase

    In the past APR worked with other manufacturers to develop a limited range of private-label exhaust systems outside the scope of APR’s internal development and manufacturing capabilities. Understanding the limits of such a program, combined with APR’s desire to deliver higher-quality products in a timely manner with better customer support, APR invested in internalizing the program. With the release of this exhaust system and the others like it, APR is pleased to present our first systems fully designed and engineered in-house from the ground up!

    Design and development begins with the use of APR’s professional grade in-house coordinate measuring machines. APR’s engineers have full access to a Romer Absolute arm with integrated laser scanner, FaroArm and Creaform 3D laser scanner for collection of special constraints surrounding the factory exhaust system. The engineers scan the vehicles and create detailed 3D maps of their design environment while designing each system in PTC Creo 3.0 CAD software.

    Using APR’s in-house stereolithography 3D printer, rapid prototypes are created for fitment on the vehicle. The design is easily and quickly verified, and if necessary, changes can be made. Once adequate clearances and fitment is confirmed, especially in areas that move under load, physical quick-cast prototypes are created and fitted for final verification through real-world use.

    APR’s world-class manufacturing partners from around the globe are responsible for manufacturing each component that falls outside of APR’s internal capabilities. Working closely with each manufacturer, APR’s engineers supply CAD models, materials specs, and other design specifications and work hand-in-hand with the manufacturer to develop the components. The end result is a collection of components, wholly unique to the APR name, awaiting final finishing, assembly and quality control at APR’s 78,000 square foot facility in Opelika, Alabama in the USA.

    The Fabrication, Finishing and Assembly Phase

    Manufacturing takes place both internally and externally to APR while finishing and assembly is completed in-house. APR’s fabrication team cuts, brushes and de-burrs premium grade T304L stainless steel piping for use in each midpipe. Then each cast component is sent through the ceramic vibrating tumblers to smooth and de-burr surface imperfections. Each component is then cleaned by hand and prepared for assembly.

    APR’s fabrication experts TIG weld each component, creating reliable, high quality and attractive welds. Each component is back-purged with argon during the process ensuring the weld is strong and consistent, as well as clean throughout. With this process complete, the APR Cast Downpipe Exhaust System is born!

    Final Quality Control

    APR has placed a large emphasis on improving quality control across various product lines, and the exhaust program is not excluded. To ensure the systems are delivered as advertised, APR’s engineers have taken a multi-step approach that encompasses many techniques that go beyond the industry standard.

    Metallurgy Testing

    APR’s engineers request full metallurgy reports with each batch of components to ensure the components are made with the T304L stainless steel grades specified on the original design prints. This information is then cross-referenced against randomly selected and independently tested samples before the components are released for assembly.

    Dimensional Inspection

    Great designs only matter if the manufacturer delivers the components as expected. To help ensure the designs are as specified, APR’s engineers randomly select components and conduct full dimensional inspections using in-house 3D laser scanning equipment. Tolerances are digitally checked against the original specifications and passed or failed based on the results.

    Fixtures

    Operating in an environment designed for accuracy and repeatability, APR’s fabrication experts leave little room for error during the final assembly phase. Jigs and fixtures, created in-house, live on custom-specified fabrication tables featuring repeatable indexing holes and extremely flat surfaces. This working environment ensures the highest level of quality control during the assembly process and safeguards against dimensional variations potentially created during the manufacturing process. The end result is a system that fits every time as it’s true to the original design specifications.
    Visual Quality

    When hand-building the products in-house, an extra level of control takes place. Components are visually checked for imperfections, and items that fall out of quality standards are rejected. The products are then packaged with care before being distributed across the world.

    APR’s confidence in the system’s quality allows for a limited lifetime warranty.


    No Comments »