Whats the problem with taking off the front "panel"?
It is quite a bit more difficult compared to just removing the bumper, and requires two pairs of axle stands, when most "home mechanics" will probably have just one pair.
The good thing about the S3 core is that it has OEM appearance, and it wont restrict air to the A/C core or the OEM Cooler, and it does give 20% decrease in inlet temp over the OEM core.
Agreed to a point. Yes, the S3 is very "OEM", however, what you forget is the fact that both the standard GTI cooler and the S3 cooler will both be subjected to heat from the air-con condensor - not a huge issue for most of time here in Blighty, but for the OP in Malta, then the a/c condensor will be chucking out a fair bit of heat straight into the S3 cooler. The is a huge advantage for the Forge.
Also, you could have an S3 core and a cat back exhaust for the price of a Forge unit.
But you have not taken labour charges into account!
I never used any axle stands. All that was needed was something to support the A/C,I/C,Radiator assembly when the Intercooler was getting removed. The job can be done with the wheels on the car and without it being jacked up 
OK, fairy nuff. But the issue is that basically there needs to be an additional method of supporting the relevent bits, be that blocks of wood, bricks, breeze blocks, or even bags of ice cubes in this chilly weather!. 
With regard to hotter countries, you may well be correct, but I can count on 1 hand the number of times I had on the A/C this year in the UK so for me at least, this is not an issue. For those in hot countries, S3 intercooler plus the likes of a twin core may be better. This has been tried and tested in the USA with good results.
Maybe you don't like using the air con, but many peeps keep their air con on permanently, and even here in Blighty, the air con can have a noticeable effect on the standard intercooler. Forge is completly isolated from this.
Furthermore, you forget that the standard cooler (GTI or S3) is bolted directly and very close to the very hot coolant radiator, and will suffer from heat conduction, at an increased rate directly proportionate to the increased requirements of IAT cooling - the harder you cane the car, the more cooling effect is required of the intercooler, but at the same time, more heat is generated by the engine and sent to the coolant rad. Again, the Forge is isolated from this. 
With regard to labour charges, the likes of Star do the core change in 2 hours now which is less than £100. Add that to the £300 purchase price, and it still costs less than half what a Forge Twintercooler costs without fitting.
Hmmmm . . . 2 hours does seem rather quick. Does that include more than one techy working at the same time?
And don't forget that the Forge could be fitted in probably a quarter of the time it takes for the S3 i/c. If you are "darn sarf", and paying higher hourly rates, then this will have a proportionally direct affect on the prices.
I do agree that the Forge is overpriced though, but it is a very good piece of kit, and can be had for £600 all in.
I actually did a guide on how I did it and my memory was obviously getting crash bar and slam panel mixed up lol.
Was that over on SCN?
Keith would be able to tell you how many people did his car. I am sure he was something like £130 to fit the intercooler and fuel pump on his car all in.
Having not done a Forge, I am not sure how long it would take, but the 2 things that take longest in the job is taking the bumper off and aligning the headlights. Even if you use the screws like you suggest, they still dont align properly when you re-install them.
Headlights wont need to be touched for the Forge.
I would be surprised if a twintercooler could be done in 30 minutes, but not done one yet
If you have never pulled off the front bumper before, then it will take longer. But if you are proficient, and know your way around, then the Forge could be fully fitted in 30 to 45 minutes, quite easily. When Forge show their cars at the likes of GTI International, they pull off the front bumpers in about 5 minutes flat!
By the way, wasnt there issues with the big intercooler core affecting the radiator efficiency on the 1.8T's?
Dunno, but again, chalk and cheese. The cooling system on the Mk5 GTI is fully electronically controlled, from the "Coolant Control Module" part of engine ECU. And the Mk5s have a more than adequate cooling system, even for towing and use in hot climes without any extra "uprating" of the cooling system required.
