Kline Innovation Valvetronic Exhaust System for Type F142 Ferrari 458 Italia

Kline Innovation Valvetronic Exhaust System for Type F142 Ferrari 458 Italia

The Ferrari 458 has become the benchmark against which all modern supercars are compared. At Kline, they decided to build the ultimate exhaust system. Their usual criteria was to create an exhaust of unparalleled performance, sound, and lightness.

The Sound

• At Kline, they perceived that the Factory exhaust for the 458 failed to capture the true magnificence of this remarkable supercar or unleash the full sonic potential of its 4.5-liter V8 engine. Beginning with a clean slate, their initial improvement involved substituting the 600cpsi catalysts with high-performance 100cpsi race catalysts, thereby minimizing gas drag coefficient, enhancing scavenging, and ultimately improving torque response and peak power output. To replace the heavy and inefficient factory silencers, they introduced their meticulously tuned silencers, which enriched both the bass and treble frequencies while significantly reducing weight. The final, and arguably one of the most crucial design elements, exclusive to Kline, was their signature tight radius laminar flow X-pipe. The resulting sound is astonishingly smooth during light driving conditions, transforming into an exuberantly spirited high-pitched roar when needed. When operating at low revs (valve closure), the gases pass through a chamber and an acoustic ceramic-filled silencer, with the cross-sections meticulously tuned to achieve optimal gas velocity and maximize torque. Under demanding loads and high revs, the valves open to unleash the engine’s full power potential.

Stainless Steel

• In the realm of exhaust manufacturing, the industry standard revolves around the use of 304-grade stainless steel. This grade offers a balanced combination of moderate strength, thermochemical stability, cost-effectiveness, and ease of production. It allows for the construction of exhaust systems that strike a practical balance between affordability and functionality, ensuring long-lasting durability. However, it’s worth noting that stainless steel is relatively heavier compared to alternative materials. Despite having a similar density to regular steel, it possesses slightly lower tensile strength. This limitation restricts the potential for creating high-performance exhaust components using stainless steel. Additionally, the thicker sidewalls required by stainless steel may result in a somewhat subdued and less vibrant exhaust note compared to other materials.

Inconel

• Inconel 625 is the ultimate choice for ensuring durability and heat resistance in the aerospace industry. This exceptional material finds extensive applications in the manufacturing of critical components, especially exhaust turbine blades for high-performance jet engines. Inconel is notably favored in Formula One exhaust systems and has been selected by manufacturers involved in prestigious hypercar projects like the McLaren P1 and Aston Martin 177. These applications greatly benefit from Inconel’s ability to withstand extreme temperatures exceeding 1000°C while prioritizing a lightweight design.
• Inconel exhibits remarkable properties, including high tensile strength and excellent thermochemical stability. Its tensile strength is comparable to that of titanium, resulting in an outstanding strength-to-weight ratio. As a result, Inconel enables the use of thin sidewall materials while maintaining structural integrity, facilitating the production of lightweight components that demonstrate remarkable resistance to fatigue over extended periods. However, working with Inconel presents certain challenges due to its difficult machinability and specific welding requirements, which demand 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 exhibits an exceptionally high tensile strength to weight ratio, surpassing that of any metal. Components with extremely low weight and high tensile strength can be molded into virtually any shape. By exclusively using aerospace and Formula 1 grade pre-preg carbon fiber, cured in an autoclave at high pressure and temperature, the company achieves the lightest and strongest carbon fiber suitable for the most extreme conditions.

Heat Shield

• For customers prioritizing effective heat management, the company offers a meticulously designed heat protection solution crafted from embossed stainless steel sheet. Skilled artisans carefully create and weld each heat shield to ensure optimal performance. Integrating these heat shields onto the manifolds allows for reduced heat soak and improved scavenging, resulting in enhanced overall performance and a cooler engine temperature.

Ceramic Coating

• Kline offers a solution for those who are concerned about heat-related issues. They have developed their own proprietary Zirconium ceramic coating process, designed to address this problem. By applying a ceramic layer to manifolds, Kline’s solution effectively reduces heat soak and improves scavenge, resulting in enhanced performance and a cooler engine.

Specifications

• Performance
  • 100 CPSI Cat Version: 14hp Increase at 8500rpm / 26nm at 4100rpm
  • Racing Version: 22hp Increase at 8500rpm / 32nm at 4100rpm
• Cross Sections
  • Catalyst / Racing Section Tubing: Dual 63.5mm OD (chosen for a balance of torque and peak power)
  • Silencer Section Tubing: Dual 63.5mm on Valve Open / Single 50mm on Valve Closed
  • 63.5mm 1D CLR Laminar Flow X-Pipe
  • Catalysts, available in 100cpsi 124mm billet, HJS race catalysts, or racing variation for more aggressive sound, and ultimate performance.
• Manifolds
  • Primaries: 45mm / 63.5mm Post Collector
  • Formula one grade true merge collectors.
• Materials
  • Full Inconel 625 (formula one grade):
    • Valvetronic Silencer Section: 6kg
      • Racing Pipes: 1.0kg Each
      • Catalyst Pipes: 3.8kg Each
  • 304 Stainless Steel:
    • Valvetronic Silencer Section: 13kg
    • Racing Pipes: 3.0kg
    • Catalyst Pipes: 4.5kg

Applications

• Ferrari 458 Italia: Type F142 (2009-2015) – 4.5L V8 Type F142

Notes

• The valves are actuated by the cars OEM vacuum system, and can be controlled by the new Kline INCONEL BUTTON wireless kit
• The included images depict the carbon fiber tips and manifolds; however, it’s important to note that these components are not part of 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, mould 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.