Kline Innovation Turboback Exhaust System for 996.2 Porsche 911 Turbo

Kline Innovation Turboback Exhaust System for 996.2 Porsche 911 Turbo

The Porsche 996 Turbo stands as one of the central models for them. Upon careful examination of the factory exhaust, they identified significant deficiencies in the design, with the sound being the most conspicuous issue. Furthermore, they found considerable potential for improvement in areas such as torque curves, peak power, and turbo lag. The factory exhaust also carries an unnecessary weight, positioned at the extreme rear of the car.

The Sound

• Their factory setup generates an uninspiring sound, mainly due to an array of chambers, 600 cell catalysts, and the most conspicuous flaw: an imbalance between opposing banks. They strongly advise that anyone considering an aftermarket exhaust for a Porsche turbo should avoid any system that doesn’t ensure some form of gas balance between the left and right banks. The replacement of the stock cats with options of 100cpsi, 200cpsi, or racing pipes increases the sound respectively. Swapping the chambered transverse rear silencer with freeflow harmonically tuned silencers enriches the sound. The addition of their trademark 1D CLR laminar flow X pipe increases the exhaust pitch beyond the range where bass noise can infiltrate the cabin. Under hard throttle and high revs, a deep and raucous sound ensues. This design, pioneered by them, has witnessed several attempted replicas.

Performance

• Given it’s a turbo car, the potential for enhancing performance via exhaust and software is immense. Their racing system offers the largest gains, an increase of 40hp and 64nm. When used in conjunction with software, they achieve improvements of 70hp and 94nm.
• 100cpsi and 200cpsi catalysts yield more modest gains of 21hp and 16hp, respectively.

Stainless Steel

• Within the exhaust manufacturing industry, 304-grade stainless steel is a common selection due to its decent strength, thermochemical stability, cost-effectiveness, and ease of fabrication. However, while stainless steel is appropriate for creating durable exhaust systems, it is heavier than other materials. Its density is similar to standard steel, but it lacks in tensile strength, limiting its application for high-performance exhaust parts. Additionally, the necessity for thicker walls with stainless steel might result in a more subdued and less vibrant exhaust sound.

Inconel

• Inconel 625 is greatly esteemed in the aerospace industry for its sturdiness and heat resistance. It’s widely employed in fabricating critical parts, notably exhaust turbine blades for high-performance jet engines. Inconel is preferred in Formula One exhaust systems and has been selected by manufacturers for prestigious hypercar projects like the McLaren P1 and Aston Martin 177. Capable of withstanding temperatures above 1000°C, Inconel centers on a lightweight design. However, working with Inconel presents unique challenges due to its intricate machinability and specific welding requirements, necessitating specialized skills and complex procedures.

Carbon Fiber

• Carbon fiber reinforced polymer, having a tensile strength-to-weight ratio that surpasses all metals, displays remarkable properties. Its lightweight nature along with its formidable strength makes it a sought-after material in various industries, including automotive and aerospace. Carbon fiber components contribute to weight reduction and offer increased stiffness, thereby enhancing overall vehicle dynamics.

Specifications

• Cross Section:
  • Racing Cross Section: 70mm OD (specifically chosen for a balance of peak torque and power)
  • Silencer Section & Cross Section: 63mm OD
  • Manifold Primaries: 41mm OD (chosen specifically for faster turbo spool)
  • Catalysts come in a variety, from 108mm OD to 127mm OD
• Materials:
  • Turboback System:
    • Standard 304 Grade Stainless Steel Weight:
      • 200 Cell Test Pipes: 14kg
      • Racing Pipes: 12.5kg
    • Inconel 625 Formula One Grade Material Weight:
    • Racing Variant: 7.0kg
    • 100 Cell Test Pipes: 10.1kg
• Manifolds
  • Standard 304 Grade Stainless Weight: 6kg Total
  • Inconel 625 Weight: 2.9kg Total

Applications

• Porsche 911 Turbo: 996.2 (2001-2004) – 3.6L TT Flat-6

Notes

• It’s of great importance to mention that, even though the images prominently display test pipes, manifolds, and carbon fiber tips, these components do not come 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, 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.