Kline Innovation Exhaust System for 996 Porsche 911 GT3

Kline Innovation Exhaust System for 996 Porsche 911 GT3

Beginning from scratch, Kline analyzed ways to improve upon the original equipment manufacturer’s (OEM) model and various existing sports exhausts. Their primary goals were to boost power, remodel and enhance the sound, and reduce the weight by half.

The Sound

• The catalyst design was the initial standout aspect for modification. By substituting this with a 200 or 100 cell sports catalyst, they achieved modest power and torque enhancements. The second design modification involved remodeling how exhaust gases interact from opposing banks. By trading the two-piece design for a single piece featuring Kline’s signature tight radius, laminar flow X pipe, they managed to change the exhaust pitch and balance out the inconsistency, resulting in a sound reminiscent of a high-revving race car. This design was originated and led by Kline, but numerous replicas have since surfaced.
• The stock silencers are bulky, weighty, and comprised of restrictive chambers, resulting in a thin exhaust note. Kline aimed to enrich the sound, enhance gas transit, and reduce weight simultaneously. Sound enrichment and weight reduction were easily achieved by simplifying the silencer design and eliminating the numerous chambers. The addition of a single chamber, volumetrically tuned for low rev resonance, removed bass noise at cruising speeds while creating a rich, loud, and high-pitched sound at hard throttle above 4000rpm.

Stainless Steel

• 304-grade stainless steel is often preferred in the exhaust manufacturing industry for its strength, thermal stability, cost-effectiveness, and ease of fabrication. However, stainless steel’s heaviness and limited tensile strength make it less suitable for high-performance exhaust applications. Moreover, the thicker walls required with stainless steel can dampen the exhaust sound.

Inconel

• Inconel 625, esteemed for its strength and heat resistance, is typically used for crucial components like high-performance jet engine exhaust turbine blades. Formula One exhaust systems and high-profile hypercar projects, such as the McLaren P1 and Aston Martin 177, prefer Inconel. Despite its heat resistance above 1000°C and focus on a lightweight design, Inconel poses unique challenges due to its complex machinability and specific welding needs.

Carbon Fiber

• Carbon fiber reinforced polymer is in high demand across various industries, including automotive and aerospace, due to its high tensile strength-to-weight ratio. This feature makes it robust yet lightweight. The addition of carbon fiber components can lead to weight reduction and increased rigidity, ultimately enhancing the vehicle’s overall performance.

Specifications

• Cross Section:
  • Cross Sections 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:
    • Pre-silencer: 63mm OD
    • Post-silencer: 57mm OD 
  • Single chamber with acoustic fill section
• Materials
  • Standard 304 Grade Stainless Steel Weight:
    • Silencers: 6kg each
    • X-Pipe: 6.1kg
    • Total: 18.1kg
    • Manifolds: 4kg each
    • Total Full System + Manifolds: 26.1kg
  • Inconel 625 Formula One Grade Exhaust Material Weight:
    • Silencers: 3.8kg each
    • X-Pipe: 3.5kg
    • Total: 11.1kg
    • Manifolds: 1.9kg each
    • Total Full System + Manifolds: 14.9kg
• Catalyst
  • 100 cell or 200 cell HJS cats are used as standard

Applications

• Porsche 911 GT3: 996.1 (1999-2001) – 3.6L Flat-6
• Porsche 911 GT3: 996.2 (2004-2005) – 3.6L Flat-6

Notes

• It’s important to clarify that despite the carbon fiber tips being prominently displayed in the images, these components 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.