Kline Innovation Valvetronic Exhaust System for LP560-4 Lamborghini Gallardo Spyder

Kline Innovation Valvetronic Exhaust System for LP560-4 Lamborghini Gallardo Spyder

The Lamborghini Gallardo, with its captivating aesthetics and a V10 engine producing 500bhp, represents the very essence of a supercar designed to stand out with its striking styling and unwavering heritage. Recognizing the opportunity to enhance this exceptional vehicle, Kline made the decision to design and construct the Ultimate Lamborghini Gallardo exhaust system, sculpted from the finest ultra-lightweight Inconel 625 material, incorporating the most innovative sound and performance design to date.

The Sound

• One of the key criticisms of the Gallardo was that its exhaust lacked the desired aggressiveness to fully embody the raw nature of the supercar. Motivated by this feedback, the team at Kline embarked on the mission to design the ultimate Gallardo exhaust. The core concept driving the design was to create an exhaust system that would truly scream at high revs while maintaining near-stock levels of quietness during cruising speeds.
• To achieve this, the exhaust was meticulously engineered to incorporate two chambered silencers during valve closure, effectively eliminating any bass drone. Upon valve bypass, the exhaust seamlessly transitions into a completely free-flow configuration, with the gases passing exclusively through Kline’s trademark 1D CLR x-pipe. The result is an exhaust note on valve open that is seriously incendiary. The x-pipe raises the pitch of the exhaust note into a raucously aggressive vocal, consistently evoking the description from customers during testing: “It sounds like a demon screaming.”

Performance

• The Kline Lamborghini Gallardo exhaust operates at the highest level of efficiency, delivering significant gains made possible through the removal of secondary catalysts and the addition of completely free-flow silencers during valve open. With 100 CPSI cats, the largest power gain achieved is 18hp at 5100 rpm, while the largest torque gain amounts to 27nm at 4800 rpm.

Stainless Steel

• Within the domain of exhaust manufacturing, the industry traditionally relies on the well-established standard of 304-grade stainless steel. This grade offers a balanced combination of moderate strength, thermochemical stability, cost-effectiveness, and ease of production, enabling the construction of exhaust systems that strike a practical balance between affordability and functionality, ensuring long-lasting durability. However, it is important to acknowledge that stainless steel, although similar in density to regular steel, is relatively heavier compared to alternative materials. Additionally, it possesses slightly lower tensile strength. As a result, stainless steel has its limitations when it comes to creating high-performance exhaust components, which may result in a somewhat subdued and less vibrant exhaust note compared to other materials.

Inconel

• When prioritizing durability and heat resistance, Inconel 625 emerges as the ultimate choice widely utilized in the aerospace industry. This exceptional material finds extensive application in the manufacturing of critical components, particularly exhaust turbine blades for high-performance jet engines. Inconel is highly favored in Formula One exhaust systems and has been selected by manufacturers involved in prestigious hypercar projects such as the McLaren P1 and Aston Martin 177. The advantages of Inconel lie in its high tensile strength and excellent thermochemical stability. Comparable to titanium in terms of tensile strength, Inconel achieves an outstanding strength-to-weight ratio, enabling the utilization of thin sidewall materials while maintaining structural integrity. This facilitates the production of lightweight components that exhibit exceptional resistance to fatigue over extended periods. However, working with Inconel presents challenges due to its difficult machinability and specific welding requirements, demanding 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.

Specifications

• Materials:
  • 304 stainless steel (18kg)
  • Ultra light weight F1 grade inconel 625 (8.7kg)
  • Comes with a choice of HJS 100cell HDPE motorsport catalysts, or a racing version for optimum performance.
• Cross Sections:
  • Catalyst Sections: 63.5mm (from the manifold joint)
  • Catalyst Diameter: 118mm
  • Silencer Section: 63.5mm
  • Valve Closure Transit: 50mm
  • Valve Open Transit: 63.5mm freeflow
  • All cross sections have been increased from stock by around 10% to give the best balance of torque, and increased power
  • 1D CLR X-pipe

Applications

• Lamborghini Gallardo Spyder: LP560-4 (2006-2008) – 5.0L V10

Notes

• The valves are actuated by the cars OEM vacuum system, and can be controlled by the new Kline INCONEL BUTTON wireless kit

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.