Kline Innovation Exhaust System for Ferrari 458 Challenge

Kline Innovation Exhaust System for Ferrari 458 Challenge

The 458 Challenge, a purpose-built race car, presented an opportunity for improvement. At Kline, it was recognized that torque response, peak power, and weight reduction could be significantly enhanced.

The Concept

• By substituting the entire exhaust system and headers with Formula One grade Inconel 625, a notable reduction in weight was achieved, along with improved crack resistance and longevity. The redesign of the headers, incorporating longer primaries, resulted in a substantial torque improvement. Furthermore, the inclusion of low drag merge collectors enhanced scavenge at high RPM, thereby increasing peak power. This enhancement enables the driver to delay shifting, offering a more dynamic driving experience.

Stainless Steel

• In the realm of exhaust manufacturing, the prevailing industry standard revolves around the utilization of 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 is important to note 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 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

• When it comes to ensuring durability and heat resistance in the aerospace industry, Inconel 625 stands out as the ultimate choice. This exceptional material finds extensive applications in the manufacturing of 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 such as 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 exceptional resistance to fatigue over extended periods. However, working with Inconel poses challenges due to its difficult machinability and specific welding requirements, necessitating specialized skills and time-consuming techniques. Additionally, Inconel’s unique properties and specialized manufacturing processes contribute to its higher cost as a raw material.

Heat Shield

• For customers prioritizing effective heat management, meticulously designed heat protection solutions crafted from embossed stainless steel sheets are offered. 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

• Weight:
  • Cat Pipe:
    • Stock: 6.6kg
    • Kline: 1.8kg
  • Tail Section:
    • Stock: 2.6kg
    • Kline: 1.8kg
  • Manifolds:
    • Stock: 12kg
    • Kline: 5.6kg
• Total Weight:
  • Total Stock: 21.2kg
  • Total Kline: 9.4kg
  • Saving: 11.8kg

Applications

• Ferrari 458 Challenge: (2011-2016) – 4.5L V8

Notes

• Although the images prominently feature the manifolds, it is crucial to emphasize that 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, 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.