Kline Innovation Valvetronic Exhaust System for 4S Audi R8 (pre-facelift)

Kline Innovation Valvetronic Exhaust System for 4S Audi R8 (pre-facelift)

The new and fresh Audi R8, featuring a formidable V10 engine, an aluminum monocoque spaceframe, and a captivating blend of striking and refined styling, stands as an impressive supercar that retains practicality for everyday use. With this dual-purpose nature in mind, the criteria for the sound and performance of the exhaust were evident: to design an exhaust system that delivers a comfortable and refined experience during cruising speeds, while also exuding a raw and powerful sound and character when revving at high RPMs.

Cross Sections

• To achieve an optimal balance of torque and increased power, all cross sections within the exhaust system have been augmented by approximately 10% compared to the stock configuration. This deliberate enhancement ensures the attainment of the best possible balance between torque and power, resulting in improved overall performance.

The Sound

• By integrating Kline’s customary innovations, including the impeccable x-pipe geometry that generates their renowned incendiary howl, the exhaust system also features a valvetronic system. This advanced technology enables you to enjoy a tranquil driving experience during cruising, while unleashing a thrilling high-pitched and aggressively resonant vocalization when the valves open. During valve closure, the exhaust gases are redirected through a series of chambers and acoustic sections, effectively eliminating any cabin noise and drone. However, when the valves open, the exhaust system transitions into a completely unrestricted flow, optimizing both performance and sound. The gases exclusively pass through the distinctive x-pipe, skillfully elevating the pitch of the exhaust note.

Performance

• By eliminating restrictions located in the silencer section and implementing a fully unrestricted flow system when the valves are open, the exhaust achieves peak efficiency. This modification not only optimizes the exhaust system’s performance but also leads to moderate improvements in power and torque output. The removal of secondary catalysts and the introduction of a free-flow design contribute to the overall efficiency and enhance the power and torque characteristics of the exhaust system. 21hp and 27 nm power and torque gain.

Materials

• The Kline Innovation Audi R8 exhaust system offers two material options: 304 Stainless Steel, weighing approximately 19.5 kilograms, and F1 Grade Inconel 625, renowned for its ultra-lightweight properties, weighing only about 9.0 kilograms.
  • Stainless Steel:
    • 304-grade stainless steel has firmly established itself as the leading industry standard for exhaust manufacturing. This specific type of stainless steel offers a well-balanced combination of moderate strength, thermochemical stability, cost-effectiveness, and ease of production. It enables the construction of exhaust systems that are comparatively affordable while delivering a high level of functionality and durability. However, it is important to acknowledge that stainless steel is relatively heavy. While it shares a similar density to regular steel, its tensile strength is slightly lower. 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 other materials mentioned previously.
  • Inconel:
    • Inconel 625 holds immense value for its indispensable role in the aerospace industry, where durability and heat resistance are of utmost importance. This exceptional material finds extensive application in the production of critical components, such as exhaust turbine blades for high-performance jet engines. Notably, Inconel is also the preferred choice for Formula One exhaust systems and has been selected by manufacturers involved in prestigious hypercar projects like the McLaren P1 and Aston Martin 177. These applications greatly benefit from Inconel’s remarkable capability to withstand extreme temperatures exceeding 1000°C while prioritizing lightweight design.
    • Inconel possesses outstanding properties, including notably high tensile strength and remarkable thermochemical stability. Its tensile strength rivals that of titanium, resulting in an exceptional strength-to-weight ratio. Consequently, 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, demanding specialized skills and time-consuming techniques. Furthermore, the unique properties and specialized manufacturing processes of Inconel contribute to its higher cost as a raw material.
  • Carbon Fiber:
    • Carbon fiber reinforced polymer exhibits an exceptionally high tensile strength to weight ratio, surpassing that of all metals. Its lightweight properties and impressive tensile strength allow for the creation of components that can be molded into virtually any desired shape. The company exclusively utilizes aerospace and Formula 1 grade pre-preg carbon fiber, which is cured in an autoclave under high pressure and temperature. This meticulous process ensures the production of carbon fiber that is both lightweight and incredibly strong, making it suitable for even the most extreme conditions.

Specifications

• Silencer Section: 65mm
• 1D CLR X-pipe
• Carbon fiber tips optional add-on

Applications

• Audi R8: 4S (2016-2019) – 5.2L V10

Notes

• Only compatible with pre-facelift models
• The valves are actuated by the cars factory vacuum system, and can be controlled by Kline’s new wireless remote INCONEL BUTTON kit
• The provided images showcase the carbon fiber tips, but 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, 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.