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Thread: XS Power Downpipes & Manifolds

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    Welly's Avatar
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    XS Power Downpipes & Manifolds

    Well, after much work being done to the downpipes.... they are now pretty much ready and won't be longer than a few weeks until available.

    I have had the previous threads on the subject locked (Thanks Tuffty) and any further discussion needs to be here.

    So.... what's been going down?

    Downpipes:

    The downpipes have had the flange modified suitably to guarantee fitment to any K04 manifold used basically. This was one of the initial problems with the pipes was the fact they simply didn't fit. Now they do.

    The 120 cell cat has been replaced with a 200 cell UK spec cat.

    The Cat and Decat pipes have been lengthened to to enable them to fit OEM systems easier.

    The problem with the second lambda boss being blanked off is now resolved - it's an open hole that will actually put the lambda probe into gas flow.

    Manifolds:

    Have now had runner 3 adapted to allow the pipework to pass the head without the need for a 'strategic dent' or any trimming of the head material.

    The flanges are now dead flat.

    I actually have a sample of both the manifold and the catted downpipe at home and I must say that they look very good indeed, very impressed with the final product compared to what it started off as.

    Here are a few photos:









    Still waiting on prices.... continue waiting patiently....
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  3. #2
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    Now this is picking up I can now let the cat out of the bag that I have been trialling the original prototype that Welly did for XS Power. The DP and De-Cat have been on for nearly 4 months with no problems what so ever.
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    bet that was eating u up inside westy lol

    nice one welly

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    Quote Originally Posted by DaveA3 View Post
    bet that was eating u up inside westy lol

    nice one welly
    It was to start with as I wanted to post up in my progress thread, but I did promise Welly I'd keep hush
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    Very interesting, thanks for your help with making this happen (to you both!)
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    Cant wait to see a manifold comparison between this and the JBS set up...
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    I still have a standard mani as an XS one wasn't available at the time and my standard one was crack free luckily. It will be interested to see what the manis will do over the crap standard one.
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    Very much so.. and what mapping is required to get the best from it all.
    I have decided to run my car as it is for a while ( no big turbo or sale for the fore seeable )so a new better manifold would be about as far as i would want to go
    Noggy Blue 2001 S3

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    Quote Originally Posted by S3 Paul View Post
    Very much so.. and what mapping is required to get the best from it all.
    I have decided to run my car as it is for a while ( no big turbo or sale for the fore seeable )so a new better manifold would be about as far as i would want to go
    Yeah. I went the K04 route and am trying to extract as much as I can from it. An exhaust mani and WMI will probably be on the cards for next year to aim towards the magic 300bhp.
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  11. #10
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    I am the only person about as far as I know that has dyno data on the XS Power manifold.

    On the dyno with the hybrid, the 034 manifold that was fitted initially, the one that very swiftly died...., she pushed out 330 BHP. This was very impressive over the original manifold's 300 BHP.

    When the 034 expired, and faced with little other options, I fitted a ported OEM K04 manifold, which Bill kindly tweaked for me. That again struggled to produce over 300 BHP.

    At this point I fitted the XS Power tubular mani. An absolutely nightmare to fit, yes. BUT, the first dyno run following the fitment, with the same mapping as the 034, the car produced 344 BHP. We settled at a consistent 338 in the end.

    The good points about the XS Power mani are the tubes being quite small for good through speed of the air, as well as a nice 4 prong Y style collector.
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    That's an insane increase of power for a bolt on mani! I think I'll definitely be getting one next year once i've seen how well they last.
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  13. #12
    Welly's Avatar
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    Quote Originally Posted by Westy View Post
    That's an insane increase of power for a bolt on mani! I think I'll definitely be getting one next year once i've seen how well they last.
    Yeah man, I've got the dyno prints somewhere, wait 1.
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    Quote Originally Posted by Welly View Post
    Yeah man, I've got the dyno prints somewhere, wait 1.
    I'm getting a little aroused just thinking about getting one of these manifolds now
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  15. #14
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    Red line is the 034 Mani, blue line is the XS Power (On a K04 Hybrid)
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




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    considering I now own that turbo, those injectors, and the exact same manifold as was used in the above plot, and also have a large port AGU as per the above plot, I can't help but feel very excited when I look at those graphs.....

    270lbft at 4k rising to 300lbft at 6000rpm, must be the most amazing feeling!
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  17. #16
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    Quote Originally Posted by Prawn View Post
    I can't help but feel very excited when I look at those graphs.....
    Excited is an understatement! HARD, is more like it
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  18. #17
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    OK, fair enough, I confess! I can't wait. it's proper lacking in power now

    if I have issues with fitting my current phase 1 XS manifold I can definitely see myself investing in the later revision!
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  19. #18
    Welly's Avatar
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    Quote Originally Posted by Prawn View Post
    OK, fair enough, I confess! I can't wait. it's proper lacking in power now

    if I have issues with fitting my current phase 1 XS manifold I can definitely see myself investing in the later revision!
    The strategic dent should allow passing past the head, so you shouldn't need to worry.

    It's just better to have it fit in the first place
    ------------------------------------------------------------------------------------------
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  20. #19
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    Quote Originally Posted by Welly View Post
    The strategic dent should allow passing past the head, so you shouldn't need to worry.

    It's just better to have it fit in the first place
    Welly, did you ever do a fitment guide for an exhaust mani?
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    Quote Originally Posted by Westy View Post
    Welly, did you ever do a fitment guide for an exhaust mani?
    No mate, that's because I truly believe deep down that it is easier (especially at home for me) to take the head off to do it....

    Not a quick guide to write, although I could probably write one from memory if I'm honest these days.

    It can be done in situ, just not a fun job.
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  22. #21
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    Quote Originally Posted by Welly View Post
    No mate, that's because I truly believe deep down that it is easier (especially at home for me) to take the head off to do it....

    Not a quick guide to write, although I could probably write one from memory if I'm honest these days.

    It can be done in situ, just not a fun job.
    Not a job i'm looking forward to I must admit!
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  23. #22
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    what is it that makes it so hard to do in situ Welly? is it the Turbo support bracket (that I don't have)? or something to do with lower access due to the transfer box on teh S3? (that I don't have)

    I'm really hoping it's something S3 specific that makes it so hard because currently, I'm not to worried, although I fear that may be about to change!

    the 3rd of the turbo-manifold bolts does indeed look to be VERY tricky on the XS, I'm guessing that, and the need for a stud havn't been altered on the new manifold?
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  24. #23
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    Quote Originally Posted by Prawn View Post
    what is it that makes it so hard to do in situ Welly? is it the Turbo support bracket (that I don't have)? or something to do with lower access due to the transfer box on teh S3? (that I don't have)

    I'm really hoping it's something S3 specific that makes it so hard because currently, I'm not to worried, although I fear that may be about to change!

    the 3rd of the turbo-manifold bolts does indeed look to be VERY tricky on the XS, I'm guessing that, and the need for a stud havn't been altered on the new manifold?
    No mate, the mani will still need at least 1 (I'd recommend all 3 really) K03 downpipe studs to be wound into the threads on the turbo and a nut on top. The running of the pipework makes it impossible for the design to be changed to a point where a bolt will go through.

    The manifold can be done in situ as I said, BUT, what makes it hard is several things. The turbo support bracket is one of them, it a pain to get it undone and to drop the turbo out of the way - that HAS to be done to make changing the manifold at all possible.

    Secondly, it's fiddly, tight and awkward for access and toolage.

    I personally think that whipping off the head, for the cost of a belt, HG and bolts is worth it (Around £100) It gives you the rare opportunity to review the status of the engine's internals which is beneficial in itself.

    Then you KNOW that it has a brand spanking HG and timing belt.

    Just my 2 cents.

    I can easily remove and refit the head in less than the time it would take me to remove and refit the manifold in situ. I know because I tried and gave up, then just took the head off!
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    Time to do the rods too then
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  26. #25
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    Quote Originally Posted by Westy View Post
    Time to do the rods too then
    There's a man who thinks ahead. A very good shout - pushing it on stock rods where you are planning to go....

    Anyway, stop polluting this thread you two!! :P
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  27. #26
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    fair enough dude, great idea on the ko3 downpipe studs, perfect idea, and dead cheap too!

    I don't have a turbo support bracket, and removing the ko3 and mani is dead easy, so no huge worries there. I'll take my chances!

    Sorry for Hijacking the thread folks!

    As you were.....
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  28. #27
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    This looks great welly Will be interested in the downpipe! I soo want to do the mani aswell but that'll just lead me onto lots of other things i cant afford, then i'll get depressed lol. But appriciate the hard work put into this!
    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

  29. #28
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    I defo want the DP, just hope the price is reasonable.

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    Quote Originally Posted by J3RV X View Post
    I defo want the DP, just hope the price is reasonable.
    Your car is never finished is it Jarvis? lol


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    Quote Originally Posted by jojo View Post
    Your car is never finished is it Jarvis? lol
    Nope, ive got a long list of things i wanna do, just crossing them off one by one. This mani does sound tempting though BUT i'm desperate for a new turbo so might give it a miss. I'm undecided whether to go with a standard or hybrid unit though

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    Quote Originally Posted by J3RV X View Post
    Nope, ive got a long list of things i wanna do, just crossing them off one by one. This mani does sound tempting though BUT i'm desperate for a new turbo so might give it a miss. I'm undecided whether to go with a standard or hybrid unit though
    You may find that your exhaust mani is cracked when you come to remove the turbo.

    If the xs mani was around in June when I replaced my turbo I would have got one fitted just as it's all off and out the way.
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    Quote Originally Posted by Westy View Post
    Now this is picking up I can now let the cat out of the bag that I have been trialling the original prototype that Welly did for XS Power. The DP and De-Cat have been on for nearly 4 months with no problems what so ever.
    Do you have a record of any airflow increase once this was fitted, or was it done at the same time as a bunch of stuff?
    '01 AMK, completely standard except for the Ambient Lighting Pack.

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    Quote Originally Posted by SiGainey View Post
    Do you have a record of any airflow increase once this was fitted, or was it done at the same time as a bunch of stuff?
    Unfortunately not mate as it was fitted the same time as a brand new K04 turbo. My bhp did go from 230 to 270 with the new turbo B5 TIP and DP/de-cat.
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  35. #34
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    Quote Originally Posted by Westy View Post
    Unfortunately not mate as it was fitted the same time as a brand new K04 turbo. My bhp did go from 230 to 270 with the new turbo B5 TIP and DP/de-cat.
    Stage 1 Westy?
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  36. #35
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    Quote Originally Posted by Alex C View Post
    Stage 1 Westy?
    Stage 2 Revo on 20psi.

    Aiming to crack the 300bhp mark next year on a standard K04, need a few choice mods including one of these manis
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  37. #36
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    manifold, WMI, largeport, and **** loads of timing!

    Job done.

    Maybe....
    -------------------------------------------------------------------------------------------------

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  38. #37
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    hmmm
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    Quote Originally Posted by badger5 View Post
    hmmm
    You're excited. I can tell
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  40. #39
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    Quote Originally Posted by SiGainey View Post
    You're excited. I can tell
    I'm glad you can tell becaus that could mean a load of different things knowing Bill
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  41. #40
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    hmmm indeed
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