Kline Innovation Valvetronic Catback Exhaust System for 8T Audi RS5

Kline Innovation Valvetronic Catback Exhaust System for 8T Audi RS5

The RS5 captivates with its striking yet elegant appearance. With a 4.2L FSI V8 engine that delivers a powerful 444hp, it exemplifies the finest in modern engineering. Recognizing the opportunity to enhance the exhaust sound and power response through tuning, the RS5 became an early focus for Kline in the development of a full exhaust system made from premium Inconel material.

The Innovation

• The first aspect that captured their attention was the condition of the manifolds. They noticed crushed and stunted primaries, the absence of any performance collector, and a 400cpsi catalyst located within the crucial power scavenge zone of the manifold. It became clear that significant improvements could be made. They understood the reasons behind the factory manifolds’ design; the limited clearance between the heads, block, and chassis presented a challenge for designing anything in that space. To address these issues, they designed long primaries and motorsport-grade collectors, resulting in drastic improvements in torque, power response, and a more balanced yet aggressive sound. They also achieved significant improvements in rev response.
• The next area they focused on was the addition of a 20-degree x-pipe to the center section. Recognizing that the car was equipped with a V8 engine featuring a cross-plane crank configuration, they knew that relieving pressure spikes associated with the uneven firing pattern could generate substantial additional power. They provided the option of a resonated (silenced) or non-resonated center section to cater to sound preferences.
• For the rear silencer section, they collaborated with the car’s stock vacuum actuated valve system to develop lightweight, valvetronic rear silencers. When the valves are open, the system allows for a completely unrestricted flow, optimizing performance and delivering an aggressive sound. When the valves are closed, exhaust gases are directed through a series of chambers and acoustic-filled sections, which are specifically tuned to enhance low RPM torque and maintain a quiet volume during cruising. They offer two options for the rear section: a mild sport mode when the valves are closed and a stock-like quiet mode when the valves are open.

Materials

• Stainless Steel:
  • 304-grade stainless steel has firmly established itself as the predominant industry standard for exhaust manufacturing. This particular grade of stainless steel offers a balanced combination of moderate strength, thermochemical stability, cost-effectiveness, and ease of production. It enables the construction of exhaust systems that are relatively affordable while providing a high level of functionality and durability. However, it is important to note that stainless steel is relatively heavier when compared to other materials. Although it shares a similar density to regular steel, it has a slightly lower tensile strength. This limitation restricts the potential for constructing high-performance exhaust components using stainless steel. Furthermore, in terms of sound characteristics, the thicker sidewalls required by stainless steel may result in a slightly less vibrant and dynamic exhaust note compared to the previously mentioned materials.
• Inconel:
  • In the aerospace industry, Inconel 625 holds significant importance due to its essential role in ensuring durability and heat resistance. This exceptional material finds extensive applications in the production of critical components, including exhaust turbine blades for high-performance jet engines. Notably, Inconel is the preferred choice for Formula One exhaust systems and has been selected by manufacturers involved in prestigious hypercar projects such as the McLaren P1 and Aston Martin 177. These applications greatly benefit from Inconel’s remarkable ability to withstand extreme temperatures exceeding 1000°C while prioritizing lightweight design.
  • Inconel exhibits outstanding properties, including notably high tensile strength and remarkable thermochemical stability. Its tensile strength is on par with that of titanium, resulting in an exceptional strength-to-weight ratio. As a result, Inconel allows for the use of thin sidewall materials while maintaining structural integrity, enabling the production of lightweight components that resist fatigue over time. However, working with Inconel presents certain challenges due to its difficult machinability and welding requirements, necessitating specialized skills and time-consuming techniques. Additionally, the unique properties and specialized manufacturing processes associated with Inconel contribute to its higher cost as a raw material.

Features

• Inconel 625 (formula one grade) or 304 Stainless Steel
• 100-CPSI / 200-CPSI catalysts are available in HJS
• Optimum balance of torque and peak power
• Weight:
  • Downpipes: 2.8kg (each)
  • Center: 3.2kg (non-resonated)
  • Rear: 3.8kg (each)
  • Total: 16.4kg
  • 31kg weight saving

Specifications

• Cross Section:
  • Cat Section: Dual 70mm
  • Center & Rear Section: Dual 70mm

Applications

• Audi RS5: 8T (2010-2016) – 4.2L V8

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.