Unitronic is proud to release its Carbon Fiber Intake System and Turbo Inlets for the C8 RS 6 and RS 7 equipped with the 4.0TFSI EA825 engine. This complete Intake System delivers massive gains of up to 58HP / 54LB-FT (Stage 2 93oct) made possible by optimizing airflow and alleviating restrictions present pre-compressor with the factory system, netting up to 99.8% more flow than stock. With five different finishes to choose from including; Gloss Carbon, Matte Carbon, Forged Carbon, Red Carbon Kevlar and Blue Carbon Kevlar, combined together with modular adapter rings on the Turbo Inlets to allow for fitments with both the stock and hybrid turbos, this Intake System allows you to personalize your engine bay with a premium look to match its superior performance.
At Unitronic, development begins with setting the objectives for performance, efficiency, aesthetics and quality. Utilizing our very own development C8 RS 6, Unitronic Engineers eagerly started 3D scanning the EA825 engine bay which helps them interact with 3D models in order to identify fitment constraints, possible new mounting locations and other component locations to ensure the final product fits perfectly within the “envelope”.
In the case of the C8 RS 6 and RS 7, the team quickly found the limits of the OEM airbox especially in tuned vehicle applications. Its narrow profile and angular design left much to be desired not only from an aesthetic perspective but especially from a performance perspective. Unitronic Engineers carefully took all aspects into consideration and designed a complete intake system which maximizes airflow to alleviate pre-compressor airflow restrictions all within the compact frontal section of the C8 RS 6 and RS 7.
EFD studies suggested uniform air velocity and air pressure profiles across the air filter entering the inlets. The bottom of the air box features a sweeping divider to help distribute air flow across the area, as it provides the same amount of air flow to each turbocharger.
Corresponding airflow velocity cross sections of the airbox entry and turbo inlet entries show a uniform profile across the areas; this suggests an unbiased supply of air between turbochargers, facilitating equalized air flow to the turbocharger compressor wheels. Power delivery between cylinder banks should meet or exceed factory tolerances.
The aesthetics of the air box are derived from organic form that optimizes function. Its design allows induction to utilize the available volume to maximize performance. The two pronounced haunches featured in the top air box promote optimum airflow over the air filter’s massive 400 square inch area.
Careful consideration was taken to minimize all aspects of turbulence that can occur during induction. Air flow separation causes this effect and thus, can potentially reduce the intake’s efficiency. Pictured in the cut plot, there are no visible signs of air separation entering the cowl as it passes through the filter, across the coupler and into the inlet; suggesting laminar flow for maximum efficiency.
As the initial designs develop; evolution begins with rapid prototyping utilizing our in-house Stratasys 3D printer. Within hours, Unitronic Engineers are able to have a complete working printed prototype, allowing for test fitments to be performed on the vehicle. Special provisions were made to ensure this intake system was able to clear the lower hood release cables and carbon fiber winglets were incorporated at both ends of the airbox in order to secure the plastic light covers, just like the OEM airbox. With five different stunning finishes to choose from, Unitronic is confident you’ll find a Carbon Fiber Intake System to suit your personal taste.
Unitronic Engineers further validated designs with their wide range of in-house development tools, equipment, and software to ensure this new Carbon Fiber Intake System flowed better and developed more power with the help of its Superflow SF-1020 Flow Bench, Maha Chassis Dynamometer, and other resources.
All of these aspects combined, result in massive gains to airflow, horsepower, and torque in tuned vehicle applications, like illustrated below utilizing our C8 RS 6 equipped with our Stage 2 ECU Performance Software, Intercooler Upgrade, and upcoming Performance Downpipes. Similar gains with the Unitronic Carbon Fiber Intake System can be observed on Stage 1 and Stage 1+ Performance Software levels, and is a required upgrade to achieve these levels of engine performance.
In addition to finding airflow limitations with the factory airbox, the factory turbo inlets were also identified as an airflow restriction. Therefore, Unitronic engineered its high-flow Turbo Inlets to alleviate restrictions and complete the package. Constructed of CNC-machined billet Aluminum, allowing for optimization of every facet of form and function while adding an unmatched aesthetic in the automotive world, the massive 74mm bore is larger than any other inlets on the market, and provides a smooth transition and seamless integration together with the Carbon Fiber Intake System. Unitronic’s unique modular turbo inlet adapter rings allow for compatibility with both the OEM turbochargers and the TheTurboEngineers TTE1020 hybrid turbos. Unique adapter rings for each set of turbochargers, perfectly machined to the compressor inlet diameters, allow for smooth, laminar airflow fed into the turbochargers for maximum performance. Finishing it off, as with all of Unitronic Performance Hardware, exceptional attention to detail and fitment results in a direct bolt-on application, including factory-style connections with the lower DV tubes and PCV connections with OEM-level precision.
Our pursuit for perfection is applied even in the most minute areas of product design and in this case, Unitronic identified that allowing for ample tolerance for engine movement on an item that is both affixed to a dynamic engine and a rigid chassis. Rather than using traditional silicone for its hose connections, this Unitronic Carbon Fiber Intake System uses a high-quality, extremely durable EPDM material for its couplers.
This offers a superior amount of flexibility over traditional silicone, while still offering, with its clever design, the rigidity and strength to be highly reliable on the 4.0TFSI engines. Taking the design and engineering one step further, Unitronic engineers created a design that allows for smooth, laminar airflow on the inside walls, while maintaining flexibility through the means of a non-collapsing structural rib profile. Unitronic EPDM couplers are designed to perfectly align with the bead rolls on the carbon fiber tubes, to ensure a perfect and seamless connection; hose clamp guides ensure perfect alignment.
This cross-sectional view of the coupler shows a 3D EFD rendering of airflow across the ribbed profiled construction. The ID of the ribs matches the ID of the interconnecting tubes for a seamless transition. As a result, even under varying conditions where flexing and stretching happen, airflow remains uninterrupted.
As with all Unitronic products, this Carbon Fiber Intake System offers superior fit and finish with a direct bolt-on fitment, retaining the factory mounting locations. For our customers convenience and to ensure this complete Intake System with Turbo Inlets is correctly installed, the Unitronic team has put together this comprehensive installation video.