Kline Innovation Valvetronic Exhaust System for Ferrari 458 Speciale

Kline Innovation Valvetronic Exhaust System for Ferrari 458 Speciale

The Ferrari 458 has become the benchmark against which all modern supercars are compared, with the Speciale model standing as its highest performing variant. At Kline, the choice was made to construct the ultimate exhaust system. Their usual criteria entailed creating an exhaust system that excels in terms of performance, sound, and lightness, setting new standards in the industry.

The Sound

• At Kline, a profound belief emerged that the Factory exhaust system for the Ferrari 458 Speciale failed to capture the true magnificence of this extraordinary supercar or unleash the full sonic potential of its 4.5-liter V8 engine.
• Commencing from the drawing board, the primary focus was on upgrading the exhaust system. The initial step involved replacing the stock catalysts with high-performance 100cpsi race catalysts. This modification effectively reduced the gas drag coefficient, improved scavenging, and ultimately enhanced torque response and peak power figures. To further enhance the exhaust system, the heavy and cumbersome factory silencers, which were primarily built to meet cost requirements, were substituted with meticulously tuned silencers. These harmonically tuned silencers enriched both bass and treble frequencies, while significantly reducing weight.
• The culmination of the design process resulted in a distinctive feature exclusive to Kline: the trademark tight radius laminar flow X-pipe. This innovation played a pivotal role in delivering exceptional sound characteristics. The resulting sound is incredibly smooth during light driving conditions and transforms into a howling, raucous, high-pitched incendiary vocal when the need arises.
• When operating at low revs (valve closure), the gases are allowed to pass through a chamber and an acoustic ceramic-filled silencer, with the cross sections carefully tuned to achieve optimal gas velocity for maximum torque output. Under demanding loads and high revs, the valves open to unleash the engine’s full power potential, ensuring optimum performance.

Stainless Steel

• When it comes to exhaust manufacturing, the industry standard revolves around utilizing 304-grade stainless steel. This grade strikes a balance between moderate strength, thermochemical stability, cost-effectiveness, and ease of production. It enables the construction of exhaust systems that are both affordable and functional, ensuring long-lasting durability. However, it’s important to note that stainless steel is relatively heavier compared to alternative materials. Despite having a similar density to regular steel, it has slightly lower tensile strength, limiting its potential for high-performance exhaust components. 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 manufacturing critical components, particularly exhaust turbine blades for high-performance jet engines. Inconel is highly favored in Formula One exhaust systems and has been selected for prestigious hypercar projects like the McLaren P1 and Aston Martin 177. These applications benefit greatly 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. Consequently, Inconel allows for the use of thin sidewall materials while maintaining structural integrity, facilitating the production of lightweight components that demonstrate exceptional resistance to fatigue over extended periods. However, working with Inconel presents challenges due to its difficult machinability and specific welding requirements, requiring specialized skills and time-consuming techniques. Additionally, Inconel’s unique properties and specialized manufacturing processes contribute to its higher cost as a raw material.

Carbon Fiber

• Carbon fiber reinforced polymer demonstrates an exceptionally high tensile strength-to-weight ratio, surpassing that of any metal. It enables the production of components with extremely low weight and high tensile strength, which can be molded into almost any shape. By exclusively using aerospace and Formula 1 grade pre-preg carbon fiber, cured in an autoclave under 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 meticulously designed heat protection solutions crafted from embossed stainless steel sheets. Skilled artisans carefully create and weld each heat shield to ensure optimal performance. Integrating these heat shields onto the manifolds reduces heat soak and improves scavenging, resulting in enhanced overall performance and a cooler engine temperature.

Specifications

• Cross Sections:
  • Cross Sections in Pre Catalyst: 57mm OD (chosen specifically to keep lambda ranges in A/F stoichiometry)
  • Post Catalyst Cross Section: 63mm OD (into 1D CLR tight radius x-pipe)
  • Silencer Sections: 63mm OD pre silencer / 57mm OD post silencer (single chamber with acoustic fill section)
• Materials:
  • Standard 304 Grade Stainless Steel Weight:
    • Silencers: 6kg each
    • Cat Section: 6.1kg
  • Inconel 625 Formula One Grade Exhaust Material Weight:
  • Silencers: 3.8kg each
  • Cats: 3.5kg
• Manifolds:
  • 2kg each

Applications

• Ferrari 458 Speciale: (2013-2015) – 4.5L V8 F136

Notes

• The valves are actuated by the cars OEM vacuum system, and can be controlled by the new Kline INCONEL BUTTON wireless kit
• While the images showcase the carbon fiber tips and manifolds, it is important to emphasize that these components are not included as 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.