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Development

  • 034Motorsport's Top Products of 2016

    034Motorsport Engineering 3D Scans for Product Development

    Looking back over the past 12 months, 2016 proved to be a year of firsts for 034Motorsport. We were able to expand our product lines to the popular Audi/Volkswagen MQB platform and bring 15 new items to fruition. Some of these include our introduction into the performance spring marketplace with the release of 034Motorsport Dynamic+ Lowering Springs for 8V Audi A3/S3 Quattro, and our first line of carbon fiber cosmetic enhancements such as the Carbon Fiber Battery Cover and Carbon Fiber Fuse Box Cover.

    Tuned B8 Audi S4 with Carbon Fiber Intake

    Additionally, we demonstrated some of the best power gains seen from a Stage 1 tune for the B8/B8.5 Audi S4 & S5 3.0T and complementary DSG software to match. Keen on staying ahead of the curve, we also acquired a brand new B9 Audi A4 test mule to begin development on Audi's newest best-selling sedan. To that extent, we have already released our B9 Transmission Mount Insert yielding the same improvements and positive feedback as its predecessor for the B8/B8.5. We're proud of every product released last year, and want to look back on a selection of Go Fast Parts that made it to the top of our Staff's "List of Favorites From 2016."

    1 | X34 CARBON FIBER MQB COLD AIR INTAKE SYSTEM 

    8V Audi & Mk7 Volkswagen Carbon Fiber Cold Air Intake

    The Carbon Fiber X34 Intake System for 1.8T and 2.0T Gen 3 MQB cars was certainly not the first aftermarket option available. Rather than deliver a subpar product first, we took our time developing an intake to be the best possible option for MQB owners. 034Motorsport's engineering department thoroughly analyzed the factory airbox and determined which components restricted airflow to the turbocharger inlet. Multiple iterations were prototyped and thoroughly tested to ensure flow was maximized from the factory inlet to the turbocharger. The result was a true, one-piece performance intake replacement with real power gains to be had. This meant each customer would receive the intake looking and performing as we intended, without any additional pieces to buy. It also ensured an easy installation with simple tools. The result? OEM+ fit and finish with the power to back it up. Our MkVII Volkswagen GTI with a stage 1 tune gained 31 WHP and 27 WTQ and stock 8V Audi S3 picked up 24 WHP and 20 WTQ respectively!

    2 | DYNAMIC+ LOWERING SPRINGS FOR 8V AUDI A3/S3 QUATTRO

    Dynamic+ Lowering Springs Suspension for 8V Audi A3 and S3

    Once the 8V A3/S3 chassis was released, we knew it would be the perfect platform to create a no-compromise lowering spring solution for vehicles equipped with Audi Magentic Ride. Built to our specifications, the front spring rate is 310 lbs/in of linear compression while the rear is slightly stiffer at 400 lbs/in. The result is our Dynamic+ Lowering Springs offering improved handling performance and precise vehicle control while maintaining OEM+ comfort levels. As for the looks, we decided on an equal 0.75" drop to improve the aesthetics of the car while still maintaining a functional ride height. Each set of Dynamic+ Lowering Springs is tested to 034Motorsport's exacting specifications to ensure they deliver unmatched performance for the discerning enthusiast.

    3 | SPHERICAL TRAILING ARM KITS FOR VOLKSWAGEN MKV/MKVI/MKVII

    8J/8P Audi & 8V/8S Spherical Trailing Arm Upgrade

    Gone are the days of pressing out rubber bushings and installing bearing holders! 034Motorsport has offered Spherical Trailing Arm Upgrades for years now, providing improved handling characteristics, steering precision, and confidence-inspiring road feel. Unsatisfied with the effort required to install the spherical bearing holders however, we went back to the drawing board and decided to make the product a complete bolt-in solution. We designed manufactured new steel trailing arms to precisely hold the high-performance spherical bearing assemblies. Now we are able to assemble everything in-house, making our re-designed Spherical Trailing Arm Kits a simple bolt-in upgrade with simple tools. Comprised of Aurora spherical bearings, billet aluminum bearing holders, and stainless steel spacers, these arms eliminate deflection under load to ensure precise handling on any road surface. Don't believe us? See our comparison between factory rubber bushings and 034Motorsport Spherical Arms below.

     

    4 | AUDI B9 TRANSMISSION MOUNT INSERT

    B9 Audi A4 Billet Aluminum Machined Transmission Mount Insert

    This product was a no-brainer to our 034Motorsport team. The widespread love for the B8 transmission mount insert made it a logical first product for our B9 A4 test mule. Once we identified the need to further lock down the transmission, we set out to create an insert and fill the void in the new factory rubber bushing. The ease of install and significant reduction in drivetrain slop make this a popular upgrade among the Audi community. We're particularly proud of this product as it represents an evolution of our billet aluminum inserts, and continues to be one of the best cost-effective upgrades to any modern Audi driver. Get an inside look on our development of the new B9 Audi Transmission Mount Insert below.

     

    5 | SUPERCHARGER PULLEY UPGRADE FOR AUDI 3.0 TFSI

    B8 B8.5 Audi 3.0T Supercharger Pulley Upgrade

    As we strive to offer the most comprehensive tuning options, the 3.0T Supercharger Pulley Upgrade was a requisite product for 034Motorsport to squeeze the most from Audi's potent supercharged V6 motor. Both our Stage 1 and Stage 2 software features an increased redline of 7,200 RPM with a refined throttle response in either Dynamic or Comfort mode. The goal was to increase power through the entire RPM range while improving upon the factory throttle modulation. Furthermore, the pulley upgrade allows for increased boost pressure from the factory Eaton TVS 1320 supercharger while staying within its maximum recommended speed for longevity. Peak gains 104 HP and 77 FT-LBS of torque can be expected from any 3.0T equipped Audi S4 or S5 running our Supercharger Pulley and Stage 2 Software on 91 octane fuel. We're proud of the usable power gains and refined driving characteristics we've safely unlocked from this supercharged engine and believe it's a must-have for any 3.0T owner.

    6 | MQB 1.8T/2.0T GEN 3 CARBON FIBER ENGINE BAY TRIM

    Carbon Fiber Engine Cover Group for MQB Chassis Audi and Volkswagen

    Yet another first for 034Motorsport in 2016! While developing the MQB X34 Cold Air Intake System, we quickly noticed the engine bay was lacking in aesthetics. After some discussion, we determined which complementary carbon fiber products could aid in bringing new life to the drab factory plastics and awful blankets under the hood. 034Motorsport's latest release of the Carbon Fiber MQB Battery Cover, Carbon Fiber Fuse Box Cover, and S3/TTS Carbon Fiber Engine Cover work together to provide a visually stunning engine bay. No longer will you be embarrassed to pop your hood! With the carbon fiber covers installed, we now find a quick peek in the engine bay to be a calming practice after a long spirited drive.

    7 | BILLET ALUMINUM REAR SUBFRAME INSERTS

    Billet Aluminum Rear Subframe Mount Insert

    The evolution of 034Motorsport's popular billet aluminum inserts continued through 2016 as we released a selection of Rear Subframe Mount Inserts for various Volkswagen and Audi chassis. These mount inserts comprehensively lock down the drivetrain without introducing significant NVH into the cabin. By filling the voids in the factory mounts, these rear subframe inserts eliminate slop associated with rubber bushings and offer a more refined driving experience. The CNC-machined billet aluminum inserts are virtually indestructible, and work to create a consistent handling car in any condition. Confidence inspiring performance with lifetime durability!

    8 | AUDI I5 TURBO EXTERNAL WASTEGATE DIAPHRAGM UPGRADE

    Upgraded classic Audi Turbo 5-cylinder external wastegate diaphragm

    Last, but certainly not least is the release of our upgraded Audi 5-Cylinder Turbo External Wastegate Diaphragm Replacement. Now discontinued from Audi, we took it upon ourselves to create an upgraded replacement for the aging factory wastegate diaphragm. Ideal for high-temperature and high-boost applications, this drop-in unit is over 50% thicker than stock and reinforced with polyester fiber. 034Motorsport was founded on the tuning of these classic Audi 5-cylinder cars and has certainly not forgotten about them.

    034Motorsport R460 8V Audi S3 Lowered on HRE Wheels

    Overall 2016 was a record-breaking year and marked many firsts for 034Motorsport. We couldn't have done it without the continued support of our 034Motorsport Dealers and customers alike. So here's to 2017, and continuing to push development on the Audis and Volkswagens we love. Let's make our cars faster and better than ever before!

  • Audi TT RS Cold Air Intake Development

    Audi TT RS Cold Air Intake in Carbon Fiber

    034Motorsport's engineers spent extensive effort developing this Carbon Fiber Audi TT RS Cold Air Intake System to yield horsepower and torque increases on the 2.5 TFSI. During the development process, many iterations were designed, prototyped, and tested, ultimately resulting in this beautifully-manufactured Carbon Fiber Cold Air Intake System.

    Developing the Carbon Fiber Audi TT RS Cold Air Intake

    It goes without saying that anything coming out of Quattro GmbH is engineered for performance. Fitted with a turbocharged inline 5 cylinder engine mated to a manual gearbox and Haldex All-Wheel-Drive System, the Audi TT RS is no exception. The vehicle makes an exceptional street car and weekend track-day weapon out of the box, but in many ways is limited in potential by some of the factory components.

    Since its debut in North America four years ago, 034Motorsport has been developing the Audi TT RS on the street and race track to extract more performance and refinement from the already capable platform. In that time, we extensively tested both factory-turbocharged and upgraded turbo vehicles to establish baselines and make comparisons between the stock airbox, aftermarket panel filters, and full intake systems.

    Preliminary Intake Testing

    Audi TT RS Cold Air Intake Testing

    When preparing our Audi TT RS for the 2013 European Car Magazine Tuner Grand Prix, we were able to show definitive improvements when replacing the factory airbox and intake tube on a big turbo configuration. While it was a preliminary test with a "dyno queen" style setup, this data helped us shape the design strategy for our production Audi TT RS Cold Air Intake System.

    Design Concept

    The 2.5 TFSI engine utilizes speed-density engine control, which meant that the 034Motorsport Audi TT RS Cold Air Intake System's design would not be limited by a MAF sensor. 034Motorsport's goal was to provide as much volume, cross-sectional area, and flow as possible from the filter all the way to the compressor inlet.

    Since Audi engineers spend a great deal of time optimizing their components, we thoroughly analyzed the factory airbox design, and took care to not reinvent the wheel in our engineering approach. This mindset helps ensure meaningful improvements resulting from calculated decisions, and usually leads to elegant, OEM+ upgrades like this air intake system. In the case of the Audi TT RS, the configuration of the factory lower airbox proved to be ideal, with its forward and side air inlets and secure mounting in the engine bay. The airbox outlet to turbocharger inlet tubing and flex sections, however, were disruptive to flow and a restriction even on stock turbo vehicles.

    Modeling the Intake

    With the aid of our in-house CMM tools, 034Motorsport engineers scanned the engine bay and critical features to better understand space constraints, and allowing them to model parts in CAD to directly replace factory pieces.

    Audi TT RS Cold Air Intake 3D Render

    The space limitations created by the firewall, high pressure fuel pump, and valve cover left us with a maximum allowable cross-sectional area equal to that of a 90mm diameter cylinder. The 034Motorsport Air Intake Tube was designed to have adequate spacing to clear the firewall and features complex organic geometry to maintain cross-sectional area while accommodating the factory valve cover and high-pressure fuel pump. This primary tube connects to the Carbon Fiber Upper Airbox Heat Shield, which interfaces with the factory lower airbox and takes advantage of factory air inlets and mounting locations.

    Working with Carbon Fiber

    Manufacturing the Audi TT RS Cold Air Intake System in carbon fiber made it possible to work with complex, organic molded shapes. 034Motorsport engineers used this to their advantage to keep the cross-sectional area of the Carbon Fiber Air Intake Tube as large as possible from the 101mm (4”) air filter to the integrated transition to the factory turbo inlet. All of the carbon fiber components also feature a fiberglass backing layer to aid in isolating cold, dense intake air from the heat of the engine bay.

    Prototyping & Testing

    Once the initial 3D CAD model was finished, prototype parts were 3D printed in house from ABS plastic for fitment verification and and performance testing. The printed the ABS plastic parts were then installed on multiple test vehicles to verify gains with various turbocharger configurations and tuning.

    Audi TT RS Cold Air Intake Prototype

    Further revisions were printed to fine tune clearances and geometry. The final revision of the intake showed peak gains of up to 16 crank horsepower and 13 ft-lbs of torque on stock turbo tunes, and over 35 crank horsepower and 24 ft-lbs with an upgraded turbocharger.

    Audi TT RS Cold Air Intake Plastic Prototype

    With the design finalized, a prototype carbon fiber intake was created and extensively tested for durability, quality, and fitment. It has now found a home on a TT RS race car through our partnership with Compass360 Racing.

    Audi TT RS Cold Air Intake Matte Carbon Fiber Prototype

    Final Production Parts

    The production version of the Carbon Fiber Audi TT RS Cold Air Intake features a gloss finish to match the factory carbon fiber trim in the 2.5 TFSI engine bay. Even the direction of the weave on the primary tube matches that of the factory pieces. At 034Motorsport, there is no such thing as a detail too small and we believe that every design aspect is important when it comes to developing our products. 

    Audi TT RS Cold Air Intake in Carbon Fiber

    Want to know more about the 034Motorsport Audi TT RS Carbon Fiber Cold Air Intake? Continue reading below to learn about individual components and see back-to-back dyno comparisons.

    Maximizing Airflow

    Audi TT RS Cold Air Intake in Carbon Fiber

    034Motorsport engineers first created a CFD-optimized carbon fiber intake tube, which is a direct, high-performance replacement for the plastic factory accordion hose. Using CAD software and 3D scanning technology, 034Motorsport was able to maximize the cross-sectional area of the intake tube while being mindful of space constraints, including the factory high-pressure fuel pump and firewall.

    Audi TT RS Cold Air Intake in Carbon Fiber

    The resulting part is a functional work of art - maximizing performance given the factory space constraints and featuring smooth transitions that ensure optimal airflow to the turbo inlet.

    Minimizing Intake Air Temperature

    Audi TT RS Cold Air Intake in Carbon Fiber

    To ensure that the 034Motorsport Cold Air Intake System draws in cool, dense air, the system includes a carbon fiber heat shield to replace the upper airbox. Bolting to the factory lower airbox, this heat shield allows the high-flow conical filter to breathe cold air from the factory inlet duct before the radiator. Both the carbon fiber heat shield and carbon fiber intake tube feature a fiberglass backing layer to aid in isolating cold, dense intake air from the heat of the engine bay.

    Performance Air Filter

    Audi TT RS Cold Air Intake in Carbon Fiber

    The 034Motorsport Carbon Fiber Cold Air Intake system houses a high-flow conical air filter with double-layer pleated cotton filtration medium. This air filter design offers increased flow through an enlarged filtration surface, while ensuring superior filtration.

    OEM+ Fit & Finish

    034Motorsport carefully selected the carbon fiber weave on the intake tube and upper airbox heat shield to match the factory carbon fiber engine trim found in the Audi TT RS's 2.5 TFSI engine bay. The 034Motorsport Audi TT RS Cold Air Intake System was designed to fit like a factory part, and mates directly to the turbo inlet pipe and factory lower airbox to provide an OEM+ look.

    Dyno-Verified Wheel Horsepower & Torque Gains

    034Motorsport's engineering and development efforts were validated on multiple vehicles using our Mustang AWD Dynamometer to ensure that the 034Motorsport Audi TT RS Cold Air Intake System provided substantial increases in horsepower and torque on both stock turbo vehicles and ones with upgraded turbo kits alike.

    Peak Wheel Horsepower & Torque with Stage 2:

    • Stock Intake: 377 Wheel Horsepower / 421 Wheel Foot-Pounds of Torque
    • Audi TT RS Cold Air Intake: 390 Wheel Horsepower / 429 Wheel Foot-Pounds of Torque

    Peak Wheel Horsepower & Torque with Stage 3:

    • Stock Intake: 460 Wheel Horsepower / 424 Wheel Foot-Pounds of Torque
    • Audi TT RS Cold Air Intake: 491 Wheel Horsepower / 443 Wheel Foot-Pounds of Torque

    Carbon Fiber Audi TT RS Cold Air Intake Features & Details

    Features:

    • Developed In-House by 034Motorsport's Engineering Team
    • High-Quality Carbon Fiber Construction
    • OEM+ Fit & Finish Matches Factory Carbon Fiber Engine Trim
    • Dyno-Proven Horsepower & Torque Gains
    • Improved Engine & Induction Sounds
    • Increased Throttle Response
    • Compatible with Stock, RS500, and APR Stage 3 Turbochargers
    • Large-Diameter CFD-Optimized Air Intake Tube
    • Fiberglass-Backed Heat Shield
    • Improved Airflow from Factory Airbox & Intake Tube
    • High Performance Pleated Cotton Air Filter

    What's Included:

    • 034Motorsport Carbon Fiber Audi TT RS Cold Air Intake Tube
    • 034Motorsport Carbon Fiber Audi TT RS Cold Air Intake Upper Airbox Heat Shield
    • 034Motorsport Double-Layer Pleated Air Filter
    • Installation Hardware

    Compatible Vehicles:

    • 2012 - 2013 Audi TTRS 2.5 TFSI (8J)

    Wheel Horsepower Dyno | Stage 2 100 Oct | 034Motorsport Carbon Fiber Audi TT RS Cold Air Intake vs. Stock Airbox

    Audi TT RS Cold Air Intake Dyno

    Wheel Horsepower Dyno | Stage 3 100 Oct | 034Motorsport Carbon Fiber Audi TT RS Cold Air Intake vs. Stock Airbox

    Audi TT RS Cold Air Intake Dyno

    Developing the Carbon Fiber Audi TT RS Cold Air Intake

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