1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

What other alternative exhaust manifolds are there for the S3?

Discussion in 'A3/S3 Forum (8L Chassis)' started by jackpilk, Feb 19, 2012.

  1. jackpilk
    Offline

    jackpilk Member

    Joined:
    Feb 11, 2012
    Messages:
    70
    Likes Received:
    0
    As a few of you may know I have a leak from the manifold area although I can't get a good look at it till Tuesday at latest, hoping it's just the turbo to manifold gasket.

    Anyway.. I've had a good search and was wondering what people replace their cracked manifolds with. I've seen the 'XS - Power' manifold crop up a few times which I've heard lots of mixed views about, and that JBS are releasing a new one soon, but is that it?

    I'm looking into this just in case mine's fudged.

    Thanks
    #1
  2. voorhees
    Offline

    voorhees Moderator Staff Member Moderator

    Joined:
    Dec 18, 2005
    Messages:
    15,018
    Likes Received:
    1,143
    I think it's the same people making the ASN lanyards
    #2
  3. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,728
    Likes Received:
    1,267
    There is currently no real alternative to the K04 mani other than the XSPower one... believe me I have been involved in trying very hard with whatever is out there and there isn't much that isn't 1) expensive or B) ****....

    034 cast manifold... showed great promise but cracked in 2 weeks of fitting
    JBS manifold... vapourware...
    Frakenturbo manifold... some initial fitment issues but seems ok... not sure how available they are as yet... Bill will know...
    TSR tubular... £600 nuff said...
    Badger5 concept K04 manifold... works but is a one off...
    XSPower... cheap, available, fitment and quality issues appear to have been sorted... actually works!

    There are a couple of other concept ones from europe but no idea on price, availability or performance

    To sum up... XS Power is about the only viable alternative that is readily available... can't speak for the Frankenturbo one as yet but I think they have doen tests and posted up on the US forums somewhere...

    <tuffty/>
    #3
  4. jackpilk
    Offline

    jackpilk Member

    Joined:
    Feb 11, 2012
    Messages:
    70
    Likes Received:
    0
    That's an answer I was looking for! I just don't want to replace it with a 2nd hand manifold because it'l no doubt crack and so will a new one (eventually) if it's still the same quality.

    So in a nutshell the XSPower would be the best shout If mine needs replacing?
    #4
  5. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,728
    Likes Received:
    1,267
    Well... there lies the question :)

    Performance gains wise then yes its one of the best manifolds out there... longevity wise??? I don't know... I have heard tales of them cracking (which tubular manis will do) but as for the new version? dunno... no one I know of has had it on the car long enough to tell... Welly would have been the yard stick on this but he sold up and went big turbo... Prawn is the next one in line for effectively testing it as he now has one on his track car....

    Stuff cracks... it gets hot... this happens... the XS Power manifold is a value for money replacement with good performance potential but don't buy it thinking it will never crack as everything will do eventually

    <tuffty/>
    #5
  6. Andrew@A.L.D
    Online

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,504
    Likes Received:
    354
    And Prawn's is a good test bed for the manifold as its trashed round a track more than the road cars on here
    #6
  7. sportstractor
    Offline

    sportstractor Chugger Regional Rep

    Joined:
    Nov 25, 2009
    Messages:
    2,715
    Likes Received:
    31
    I'm in the same boat. Iv got a cracked manifold, which seals up after a minute or so. Got a good deal on the xs power manifold, downpipe and sportscat and went for it. Going to get it remapped again after fitment as it will be ready for stage 2, will hopefully be able to ensure egts don't get out of hand. No one can say how long it will last, but if it lasts the 2 years I'm probably going to keep mine for, il be happy
    #7
  8. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,439
    Likes Received:
    1,281
    I'm very keen to see if mine cracks, as mine is the older V1 manifold!

    I['ve not heard of people cracking them before myself, but I am of course open to the fact that it could happen.

    If it does crack, it's nice to know I can get the new V2 XS manifold at such a reasonable price though, and changing it over isn't too tough a job really either.
    #8
  9. sideways steve
    Offline

    sideways steve Member

    Joined:
    Dec 20, 2011
    Messages:
    347
    Likes Received:
    5
    I used to have this issue on turbocharged MX5's where the cast manifolds would always crack. The solution was to add in relief cuts around the bolt homes and between eack of the runners and it then allowed it to expand and contract without cracking.

    I have not seen a photo of an S3/A3 T manifold off a car but if someone could post one up I may be able to advise if the same solution would work. Obviously this would only be helpful if your manifold is still ok just now.
    #9
  10. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,728
    Likes Received:
    1,267
    K04 mani's tend to crack at the collector as this is the main bottle neck...

    [​IMG]

    <tuffty/>
    #10
  11. Welly
    Offline

    Welly VX220 SC Driver :)

    Joined:
    Aug 5, 2009
    Messages:
    10,699
    Likes Received:
    117
    Mine did 5000 miles of very very hard road driving, and, although black when removed, was still in good condition. No warpage, no crack, and it certainly saw some heat.
    #11
  12. jitvv
    Offline

    jitvv Member

    Joined:
    Oct 18, 2006
    Messages:
    175
    Likes Received:
    33
    Where can i get a XS power manifold?Cheers
    #12
  13. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,439
    Likes Received:
    1,281
    #13
  14. jitvv
    Offline

    jitvv Member

    Joined:
    Oct 18, 2006
    Messages:
    175
    Likes Received:
    33
    Sorry mate, i thought someone off here was selling them, Thanks for that mate :)
    #14
  15. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,439
    Likes Received:
    1,281
    Hope that didn't come across as rude, it's just the first opportunity I've had to use that link in ages :p

    Sam Bryant on here is indeed selling them, from the USA
    #15
  16. Jimgrim77
    Offline

    Jimgrim77 Member

    Joined:
    Nov 6, 2011
    Messages:
    959
    Likes Received:
    20
    He sure is. I paid £197 for the mani delivered. Took 3 days to arrive via FedEx. Couldn't me more impressed with product or the results.
    #16
  17. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,728
    Likes Received:
    1,267
    Sam has been in touch for a potential group buy... I am waiting on the details...

    <tuffty/>
    #17
  18. Jimgrim77
    Offline

    Jimgrim77 Member

    Joined:
    Nov 6, 2011
    Messages:
    959
    Likes Received:
    20
    Check his Facebook page
    #18
  19. Andrew@A.L.D
    Online

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,504
    Likes Received:
    354
    Just got a Email of JBS saying there cast manifolds are now out on the market

    Good Afternoon,

    It has been a long time coming, but the time is finally here…
    Straight from the burning fires of the forge comes JBS Auto Design’s K04 Cast Manifold!


    [​IMG]













    We very much appreciate your patience over these last few months and as promised, we are contacting everyone who has made previous enquiries about this manifold, and will be offering a 10% discount off the RRP!
    The price of our K04 Manifold to you lucky select few will be £405 inc vat.

    The manifold will not be available for general sale until 3 days after this email has been sent. This should allow everyone who expressed a prior interest to get their order in before new orders start to pile up.

    When you place your order you will receive the following items:

    • JBS K04 Cast Manifold
    • 3 Bolts and 3 Washers
    • Manifold to head gasket
    • Manifold to turbo gasket
    As it has been such a long time and just in case you have forgotten, here is some information on the K04 Manifold:

    From what JBS has learnt from the development of the K03, the design process for the new K04 OEM performance upgrade manifold became a lot simpler.
    Casting the new manifold gives better quality mass production and for such a constraint bound design as the K04 manifold, casting gives fewer constraints on the pipe bend radius, allowing the runner to flow freely. The most obvious improvement over the standard cast manifold being the increase in bore (diameter) of the runners all the way into the collector.
    [​IMG]













    Like the new K03 design, the manifold has been designed in CAD to optimise the design, flow capabilities and to enable easier fitment. The CAD process allows the designers at JBS to manipulate the part quickly, while allowing information and measurements to be taken easily.
    [​IMG]














    JBS K04 SPEC

    The main work has taken place increasing the diameter of the runners all the way to the collector and the design of the collector to achieve best flow. The manifold has been designed to have maximum material around the bolt holes to prevent cracking, found on the OEM and competitors manifolds. The collector design also separates the runners to reduce port sharing of combusted gasses, aiming them towards the turbine in the turbo.


    [​IMG]


















    The box collector features cooling fins to minimise the effects of EGT’s on the manifold, preventing the manifold from warping and causing thermal fatigue.

    [​IMG]













    Fitment of the manifold was also a large considerationand the area around the head studs and nuts was maximised to enable fitment.

    [​IMG]












    The cylinder head flange uses the same design as the K03 to allow greater thermal expansion and movement between the runners. It has been found that a restrictive flange forces stresses back through the runners of the manifold which can lead to crack propagation.

    Recently there has been a lot of talk about performance manifolds cracking due to poor design, weak materials and the stress the manifolds are under due to high exhaust gas temperatures. We are confident in the design of the new manifolds due to the hours spent on CFD (computational fluid dynamics) analysis and prototyping.

    To ensure the manifolds don’t suffer from poor material choice and casting quality, we have chosen to cast these manifolds in a very high quality foundry which is used by many OEM turbo suppliers and OEM vehicle manufacturers such as BMW and GMC. This will ensure the castings are of the highest quality.

    Also to reflect the high quality casting, we have spent a great deal of time researching the latest high temperature resistant cast irons. These cast irons have high nickel content and having the following properties makes them ideal for our performance manifolds: resistance to corrosion, resistance to oxidisation and high temperatures (up to 1050 ⁰C) and a resistance to wear and erosion. This ensures a minimal amount of thermal expansion and an equal rate of thermal expansion to the turbo housing. This again minimises the potential for thermal fatigue or cracking. The bolts required for the fitment of the turbo to the manifold are also supplied, as they are a specific size and made of a material to prevent stretching which can lead to blowing gaskets.



    We wish to thank you for your patience once again and welcome any questions or queries you may have.

    I look forward to hearing from you in the near future.


    Kind Regards,

    Jonny Close
    Customer Relations Manager
    #19
  20. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,553
    Likes Received:
    1,074
    'We very much appreciate your patience over these last few months and as promised..'

    HA!
    #20
  21. Andrew@A.L.D
    Online

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,504
    Likes Received:
    354
    thats what i was thinking. I wanted this manifold a year and a half ago
    #21
  22. Westy
    Offline

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,295
    Likes Received:
    969
    JBS must have rushed the final stages of this. They must know about the XS ones flooding the market and they don't want to miss out.
    #22
  23. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,728
    Likes Received:
    1,267
    My initial feeling is that the XS Power will be better performance wise... longevity? anyones guess...

    While JBS state they have worked on the runners etc in the design, initial versions still had that lump of metal in the collector that restricted flow so EGT's are likely to remain high at that point... the XS power has no such restriction... time will tell I guess

    <tuffty/>
    #23

Share This Page