Kline Innovation Valvetronic Exhaust System for 4S Audi R8 (facelift / OPF)

Kline Innovation Valvetronic Exhaust System for 4S Audi R8 (facelift / OPF)

The 2020 Audi R8, equipped with its v10 engine, aluminium monocoque spaceframe, and a captivating blend of striking yet refined styling, represents a formidable supercar that also offers the refinement suitable for daily driving. Considering this dual-purpose nature, the sound and performance criteria for the exhaust system were clearly defined: to design an exhaust that delivers a comfortable and smooth experience during cruising speeds, while also producing a raw and powerful sound that matches the car’s nature and performance when revving at high RPMs.

Cross Sections

• To achieve an optimal balance between torque and increased power, every cross section within the exhaust system has been enlarged by approximately 10% compared to the stock configuration. This deliberate enhancement ensures the achievement of the finest equilibrium between torque and power, resulting in improved overall performance.

The Sound

• By incorporating Kline’s renowned innovations, including the meticulously crafted x-pipe geometry that contributes to their acclaimed and exhilarating engine sound, the exhaust system seamlessly integrates a valvetronic system. This advanced technology ensures a serene driving experience during cruising, while also unleashing a thrilling, high-pitched, and aggressively resonant vocalization when the valves are open. When the valves are closed, the exhaust gases are skillfully redirected through a series of chambers and acoustic sections, effectively eliminating any unwanted cabin noise and drone. However, upon opening the valves, the exhaust system seamlessly transitions into a completely unrestricted flow, optimizing both performance and sound. The gases flow exclusively through the distinct x-pipe, expertly enhancing the exhaust note with an elevated pitch.

Performance

• By eliminating restrictions within the silencer section and implementing a fully unrestricted flow system when the valves are open, the exhaust system achieves peak efficiency. This modification not only optimizes the performance of the exhaust system but also leads to moderate improvements in power and torque output. The removal of secondary catalysts and the introduction of a free-flow design play a significant role in enhancing overall efficiency, ultimately elevating the power and torque characteristics of the exhaust system. 21hp and 27 nm power and torque gain.

Materials

• The Kline Innovation Audi R8 exhaust system is offered in two material options: 304 Stainless Steel or the ultra-lightweight F1 Grade Inconel 625, weighing approximately 10.5 kilograms.
  • Stainless Steel:
    • 304-grade stainless steel has firmly established itself as the prevailing industry standard for exhaust manufacturing. This specific type of stainless steel offers a well-balanced combination of moderate strength, thermochemical stability, cost-effectiveness, and ease of production. It enables the construction of exhaust systems that are relatively affordable while delivering a high level of functionality and durability. However, it is important to acknowledge that stainless steel is relatively heavier compared to other materials. While it shares a similar density to regular steel, its tensile strength is slightly lower. This limitation restricts the potential for constructing high-performance exhaust components using stainless steel. Additionally, in terms of sound characteristics, the thicker sidewalls required by stainless steel may result in a slightly less vibrant and dynamic exhaust note compared to the materials mentioned earlier.
  • Inconel:
    • In the aerospace industry, Inconel 625 holds immense value due to its indispensable role in ensuring durability and heat resistance. This exceptional material finds extensive application in the production of critical components, including exhaust turbine blades for high-performance jet engines. Notably, Inconel is the preferred choice for Formula One exhaust systems and has been selected by manufacturers involved in prestigious hypercar projects such as the McLaren P1 and Aston Martin 177. These applications benefit significantly from Inconel’s remarkable capability to withstand extreme temperatures exceeding 1000°C while prioritizing lightweight design.
    • Inconel exhibits outstanding properties, including notably high tensile strength and remarkable thermochemical stability. Its tensile strength rivals that of titanium, resulting in an exceptional strength-to-weight ratio. Consequently, Inconel enables the use of thin sidewall materials while maintaining structural integrity, allowing for the production of lightweight components that resist fatigue over time. However, working with Inconel presents certain challenges due to its difficult machinability and welding requirements, demanding specialized skills and time-consuming techniques. Additionally, the unique properties and specialized manufacturing processes associated with Inconel contribute to its higher cost as a raw material.
  • Carbon Fiber:
    • Carbon fiber reinforced polymer showcases an exceptional tensile strength to weight ratio, surpassing that of all metals. Its lightweight properties and impressive tensile strength allow for the fabrication of components that can be molded into virtually any desired shape. Our company exclusively utilizes pre-preg carbon fiber of aerospace and Formula 1 grade, which undergoes a meticulous curing process in an autoclave under high pressure and temperature. This precise manufacturing technique ensures the production of carbon fiber that is not only lightweight but also remarkably strong, making it suitable for even the most demanding and extreme conditions.

Specifications

• Silencer Section: 65mm
• 1D CLR X-pipe

Applications

• Audi R8: 4S (2019-2024) – 5.2L V10

Notes

• Only compatible with facelift models equipped with OPF
• The valves are actuated by the cars factory vacuum system, and can be controlled by Kline’s new wireless remote INCONEL BUTTON kit
• Although the carbon fiber tips are prominently featured in the images, they are not included in the standard package

About Kline Innovation

At Kline, exhaust design is approached with utmost seriousness. The company adopts a no-compromise stance when it comes to delivering a product that meets the highest standards and satisfies customers’ expectations. Kline offers a comprehensive original equipment design and manufacturing service. Starting from provided drawings or design briefs, the team utilizes advanced 3D modeling techniques to create final designs. They also provide valuable consultation during the process and are capable of manufacturing tooling and fixtures for production, as well as handling final production runs, particularly catering to low to medium volume needs. Kline’s commitment to excellence ensures that customers receive a top-quality product without any compromises.

Development

• All projects at Kline are executed entirely in-house, utilizing a diverse range of processes. These internal capabilities include laser scanning, CNC laser cutting, CNC mandrel bending, tubing and silencer manufacturing, CNC welding, pressings, CNC milling, mold manufacturing, and autoclave carbon fiber production. Notable automotive clients, such as W Motors with their Fenyr Supersport, Corbellati Missile, and RUF Automobil, have recently collaborated with Kline.
• Kline has expanded its design and manufacturing process by incorporating laser scanning capabilities. This valuable addition enables the team to achieve enhanced precision in both design and quality control, resulting in an exceptional end product for customers. The adoption of laser scanning technology at Kline showcases the company’s unwavering dedication to delivering superior outcomes.