Kline Innovation Turboback Exhaust System for 997.1 Porsche 911 Turbo

Kline Innovation Turboback Exhaust System for 997.1 Porsche 911 Turbo

The 997 turbo holds a prominent place in Kline’s line-up. An exhaustive review of the factory exhaust revealed significant flaws in the design, with sound being the most glaring issue. However, torque curves, peak power, turbo lag, and the potential for a 65% weight reduction also emerged as areas ripe for improvement.

The Sound

• The factory setup produces an unimpressive sound, largely due to the numerous chambers, 600 cell catalysts, and an imbalance between opposing banks. By substituting the stock cats with 200cpsi, 100cpsi, or racing pipes, the sound volume is enhanced. Furthermore, by replacing the chambered transverse rear silencer with freeflow harmonically tuned silencers, the sound is enriched. Adding Kline’s signature 1D CLR laminar flow X pipe increases the exhaust pitch to a level where bass noise can’t infiltrate the cabin. Under hard throttle and high revs, a rich, loud sound is produced. This design innovation is attributed to Kline.

Performance

• For a turbo forced induction flat 6, the prospects of enhancing performance through exhaust and software modifications are substantial. The most significant improvements with Kline’s racing system are 42hp and 65nm. Paired with software, these figures rise to 75hp and 102nm. The 100cpsi and 200cpsi options yield smaller gains of 16hp and 21hp, respectively.

Optional Tails

• These are crafted in-house using authentic aerospace-grade carbon fiber, which is then cured in an autoclave at 10 bar.

Stainless Steel

• While 304-grade stainless steel is frequently chosen in the exhaust manufacturing industry due to its strength, thermal stability, affordability, and fabricability, its weight and limited tensile strength may limit its use in high-performance exhaust parts. Additionally, the need for thicker stainless steel walls might compromise the exhaust sound.

Inconel

• Inconel 625, known for its durability and heat resistance, is commonly used to create essential parts like high-performance jet engine exhaust turbine blades. It’s the go-to material for Formula One exhaust systems and renowned hypercar projects such as the McLaren P1 and Aston Martin 177. Although Inconel can endure temperatures over 1000°C and focuses on lightweight design, it requires specialized skills due to its complex machinability and specific welding requirements.

Carbon Fiber

• Carbon fiber reinforced polymer is highly sought after across industries like automotive and aerospace due to its impressive strength-to-weight ratio. Its integration can contribute to weight reduction and increased stiffness, ultimately improving the overall performance of the vehicle.

Specifications

• Cross Section:
  • Racing Version 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 pest pipes: 14.5 kg
      • Racing Version: 12.5kg
    • Inconel 625 Formula One Grade Material Weight:
      • Racing Version: 7.2kg 
      • 100 cell test pipes:10.2kg
  • Manifolds
    • Standard 304 Grade Stainless Weight: 6kg total
    • Inconel 625 Weight: 2.9kg total

Applications

• Porsche 911 Turbo: 997.1 (2006-2008) – 3.6L TT Flat-6

Notes

• While the images feature the test pipes, manifolds, and carbon fiber tips quite prominently, it is crucial to highlight that these components do not come with 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.