Hi-Flow, Carbon Fibre Airbox for Audi C7 RS6/RS7 and S6/S7

Forge Motorsport are excited to launch our RS6 Carbon Fibre Air Box, another superior product to be released in our ‘Hi-Flow’ range.

With this unique sleek design, you can expect to see a carbon fibre housing that flows beautifully along the engine bay, giving you more horse power and torque, and hopefully an appreciation for the care and time that has gone into the production.  

• The carbon fibre parts were created from a mould that was hand finished and refined by one of our many skilled craftsmen at Forge Motorsport HQ in Gloucestershire, England.  
• The smooth, flowing edges were created from military grade foam.  
• The plug was finalised, and a 3D scan was taken enabling us to start the long process of developing the billet tooling for manufacturing.

Once the initial carbon fibre sample was developed, we fitted the intake to the Audi development vehicle for rigorous testing. A few small changes were made to ensure we provide our customers with the best possible fitment and performance.

With the design process complete, we wanted to be sure we delivered the best quality product we could and following the extensive design and development of this intake, we enlisted the services of one the world’s leading carbon fibre manufacturers, whose products range from F1 aero, carbon fibre car bodies, and aircraft wings!  

• Rather than using a vacuum (also known as liquid infusion) to draw the resin through the mould then pulling the raw carbon fibre cloth to the mould shape, a technique known as Autoclave is used in the manufacturing of this beautifully designed product. This involves the use of up to 10bar of pressure that is blown into a 100% billet mould to force the material out. This high amount of pressure ensures the carbon fibre is fully in contact with the surface of the mould.  
• Therefore, making sure the weave is tight, solid and strong; this process will also ensure there are no imperfections in the product.
• The mould is then heated to cure the resin which in turn gives a tensile strength up to 8 x stronger than mild steel but at a fraction of the weight.

All the Forge Motorsport hoses supplied in this Hi-Flow intake have been designed with 4 layers of ply.  

In the development of this intake we also created our own custom moulds for the Forge silicone hoses. This allows for the ease of fitting and transition of flow throughout the air box internal surface.

• The construction of the silicone has been