APR is pleased to present the ultimate Cast Inlet Downpipe Exhaust System for AWD 1.8T and 2.0T vehicles!
The APR Cast Inlet Downpipe Exhaust System replaces the restrictive factory downpipe with a larger, 76mm stainless steel mandrel-bent system, featuring a port-matched cast inlet, high-flow catalyst and various other features. Expect better throttle response, more horsepower and an intoxicating exhaust note, while remaining civilized during normal daily driving. It’s one of the best performance upgrade for 1.8T and 2.0T engines following APR’s ECU Upgrades and it’s designed and assembled in-house, using premium materials and world-class manufacturing techniques few can match.
Downpipe with Cast Inlet
The APR downpipe features an investment-cast inlet, with a port matched v-band flange, creating an ideal flow path for exhaust gasses exiting the turbocharger. By matching the already oversized turbo outlet, the downpipe is able to maintain exhaust gas velocity, improving performance with minimal variances in cross-sectional area due to the strategic use of cast parts. Furthermore, the cast inlet allows for excellent packaging, satisfying other design criteria while maintaining a larger and constant cross-sectional area compared to mandrel bent tubing built to similar specifications. The end results it simple: Smooth exhaust flow and maximum performance!
The downpipe’s piping is upgraded to attractively-brushed, straight-through and mandrel-bent 76mm tubing, dwarfing the small 65mm factory system. Furthermore, components visible from the engine bay are tumbled for a more attractive finish. A CNC laser cut bracket provides a strong and accurately positioned mounting point to take the weight of the downpipe off the turbocharger, and the internally-corrugated flex section gives the downpipe the flex it needs under engine movement. Finally, the downpipe uses T304L stainless steel components that are TIG welded together with argon back-purging, ensuring the system not only looks great on the inside and out, but stands the test of time.
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 new system 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 sends each cast component 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 Inlet 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.
APR’s engineers request full metallurgy reports with each batch of components to ensure the components are made with the material 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.
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.
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. 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.
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.
Vehicle Engines Transmission Drivetrain Driver Side Part Number Price
AWD = Four wheel drive. LHD = Left hand drive. RHD = Right hand drive.
1.8T models may require a smaller 60mm reducer for stock catback compatability.
Audi A3 / S3 (MK3 / Typ 8V) 1.8T & 2.0T 6MT & S-Tronic Quattro / AWD LHD & RHD
Audi TT / TTS (MK3 / Typ 8S)*Requires modification to midpipe length. 1.8T & 2.0T 6MT & S-Tronic Quattro / AWD LHD & RHD
Skoda Octavia / VRS (MK3 / Typ 5E) 1.8T & 2.0T 6MT & DSG 4x4 / AWD LHD & RHD
Volkswagen Golf / Alltrak / Golf R (MK7 / Typ 5G) 1.8T & 2.0T 6MT & DSG 4 Motion / AWD LHD & RHD
Volkswagen Tiguan (MK2 / Typ 5NA) 1.8T & 2.0T 6MT & DSG 4 Motion / AWD LHD & RHD
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