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XS Power K04 Manifold for 210/225 S3

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Sep 8, 2010.

  1. Welly
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    Welly VX220 SC Driver :)

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    [Sep 8, 2010]
    Morning all.

    I have taken delivery of an XS Power/Relentless K04 Exhaust Manifold for the S3 210 and 225. Basically, any car with the K04-022.

    Same goes here as did in my other thread http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/102665-email-xs-power.html. I will be reviewing this, giving XS Power some suggestions on where it can be improved etc, therefore making it a well worthy buy.

    Initial thoughts are good. Very well made, and nicely welded together. My main concern, as was always going to be is the turbo flange. One of the flange bolts holes would be very tricky to get to. And I mean very tricky indeed. I have a mate who is going to knock me up some studs to wind into the turbo for testing purposes and then I will go from there.

    I have managed to bolt it to the turbo to mock up the fitment. All the flange holes are spot on which is a good start.

    I will update this thread as things happen. Didn't have much working time last night as her indoors wanted me to watch Eastenders. Deep joy.

    Photos:

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    #1
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  3. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 8, 2010]
    looks like a challenge that one bolt/stud fixing
    you tried it in situ onto a head yet welly?
    #2
  4. Welly
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    Welly VX220 SC Driver :)

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    [Sep 8, 2010]
    Not yet, I was going to try it on one of your spares to see what fitment was like. When are you back anyway dude?

    And, more to the point, what are you bloody doing on here? :lmfao:
    #3
  5. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 8, 2010]
    back saturday, back in w'shop sunday

    ... and i am sad.. cant stay away or switch off car stuff
    #4
  6. Welly
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    Welly VX220 SC Driver :)

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    [Sep 8, 2010]
    LOL, I know that feeling. OK - will pop up and see you on Sunday for a natter about the above.

    PS. You're out of milk.
    #5
  7. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 8, 2010]
    interesting know Bill has showed me the 034 motorsport manifold it will be interesting to see how this works out
    #6
  8. Welly
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    Welly VX220 SC Driver :)

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    [Sep 8, 2010]
    Going to start looking at this properly tonight and see where we get.
    #7
  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 8, 2010]
    I am at the unit until 4ish today mate and from 10 till 4 ish for the rest of the week if you wanna pop over..

    <tuffty/>
    #8
  10. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 8, 2010]
    Shiney mate, liking it.

    I see they slotted the one hole, at least that's easier. It's what i was going to do to fit one to mine before i bought a cheapo cast one instead.

    Nail it on mate, nowt to lose
    #9
  11. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 8, 2010]
    This is looking very tempting
    #10
  12. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Sep 8, 2010]
    I remember a tig art manifold like this... was a real ball ache to fit with the engine in situ,
    I remember the only wat realy was to fit the turbo to manifold, then mani to the head ... then the head to the car.
    That bolt on the flange involved some chopping and welding of a spanner to get a nut on. BUT it was a pain and kept coming loose.
    Hope this works out.
    #11
  13. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 8, 2010]
    Looks a good piece of kit, lets hope yoiu can work your magic welly as i think my manifolds cracked :(.
    #12
  14. Welly
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    Welly VX220 SC Driver :)

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    [Sep 9, 2010]
    Good evening good peoples.... we have some developments on this.

    It is fit-able.

    Well, potentially at least. I have managed to fit the manifold to the turbo off the car with success. Not easy though. And not possible with OEM equipment.

    Lets start at the beginning. The issue with this manifold was always going to be one thing in particular. The turbo flange. Bolting the thing to the head should be easy by comparison to an OEM one as there is endless room to get hands/tools through.

    Permit me to demonstrate:

    [​IMG]

    [​IMG]

    This particular hole in the flange will be the hard one, as access is nil.

    Totally impossible to get an OEM bolt in here. There is no way it can be done. End of.

    As mentioned earlier in the thread, I had a good mate of mine (he's on here also but I don't know his name as he is new), George, knocked me up some CNC machined Stainless Steel studs for a mock up assembly.

    He produced the following (good lad :thumbsup:)

    [​IMG]

    Just the job for fitting this sucker.

    Studs are wound into the turbo flange, and then the manifold mated on top. These first attempt studs are actually a little shorter than they need to be. Between 3 and 5mm needs to be added to the top to allow the nut to clamp down to the stud properly. He is going to do me another 2 sets of 3, one with 3 mm added and one with 5 mm added and then I will decide what's best to use.

    Anyway - 3 M10 nuts required for this - the first 2 being easy to fit on and tighten. The third, being the one pictured above is a fiddle to get the nut on and threaded. However, it is do-able and you can also get a 17mm spanner in there to tighten the nut up. Tight as a gnat's chuff though. I will be 'manufacturing' a special tool for doing this, as I think it can be made easier with the correct bodge.

    At this point I think it is only fair to mention that XS Power's claim that the downpipes they supply (that haven't historically fitted with the OEM manifold) do fit with this tubular one as they stated.

    Here are some photos of the turbo and manifold bolted together properly.

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    [​IMG]

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    This is the one that is a bit of a biatch to get to....

    [​IMG]

    All points go.

    The only real way to test this is to use it and see what happens with prolonged use. Potential failure will be highlighted then.

    I will be checking the fitment to a 1.8T head on the weekend so will get back to you with that info.
    #13
  15. Welly
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    Welly VX220 SC Driver :)

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    [Sep 9, 2010]
    #14
  16. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Sep 9, 2010]
    Have you tried fitting the O2 sensor as this is very close to the standard manifold with the XS down pipe
    #15
  17. Welly
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    Welly VX220 SC Driver :)

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    [Sep 9, 2010]
    Yep, there was enough clearance.
    #16
  18. Welly
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    Welly VX220 SC Driver :)

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    [Sep 10, 2010]
    Does anyone know if you can get a high heat thread lock? Loc Tite's highest temp stuff is ~500 degrees.
    #17
  19. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 10, 2010]
    I had one of those weld itself to my turbo and mani and blow through the middle, i had to scrape and file to get the residue off,lol

    Stuck a used OEM one ( as its all i had) and she is fine atm.

    But seeing you are going to be dropping it off biweekly to reweld, changing the gasket won't be a problem....LMAO

    Hows that silly expensive pipe? Fitted?
    #18
  20. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 10, 2010]
    #19
  21. Welly
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    Welly VX220 SC Driver :)

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    [Sep 10, 2010]
    Hopefully not..... :(

    But like I said, that's the only way to test it to be fair. Use and abuse.
    #20
  22. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Sep 10, 2010]
    Last edited: Sep 10, 2010
    #21
  23. ricko
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    ricko Member

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    [Sep 10, 2010]
    i have the same manifold on my a3, it's been on for about 6 months now i'll take some pic's for ya. the problems i found were like you said the one nut that you cann't get to. but i also found it moved the turbo back so i had to get new oil line's made up. oh and it gets bloody hot, i'll try and put some pic's up tomorrow
    #22
  24. Welly
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    Welly VX220 SC Driver :)

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    [Sep 10, 2010]
    The same manifold on an A3? Is your A3 K04 equipped dude? Anyway, pics would be great if you don't mind.

    Impressed that you've been using it for 6 months without issue.
    #23
  25. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 10, 2010]
    nordloc washers
    #24
  26. ricko
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    ricko Member

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    [Sep 11, 2010]
    i took some pic's for ya, i'll try and put them on after. yes it has got a ko4 on it, the only worry i have is like i said it gets very hot and there's lots of bits and bob in that area. i think am going to try and get it coated next summer, like i said you might have to get longer oil line's made up but am not 100% because your old manifold is nothing like mine
    #25
  27. Welly
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    Welly VX220 SC Driver :)

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    [Sep 11, 2010]
    It'll be fine on the S3, it's designed to have the K04 as standard, where as your engine layout isn't.

    Pics still would be good though. :thumbsup:
    #26
  28. ricko
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    ricko Member

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    [Sep 11, 2010]
    well i know that now lol. I cann't work out how to post the bloody picture's cos i is well fick an dat. could i email them to you i think i can do that:wacko:
    #27
  29. Lemon S3
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    Lemon S3 Alex

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    [Sep 11, 2010]
    Create an account with photobucket.com then upload your images n it will give you an IMG Code then just copy n paste that on here.
    #28
  30. emery1990
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    emery1990 Active Member

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    [Sep 12, 2010]
    Did you notice any gains from the new manifold? From reading up about after market manifolds ( different car ive got but still probably the same on others) is that they take away torque from the bottem end and put it right up the top of the rev range, being good if you've got a race engine that revs high ? This is the reason im now selling my after market one and staying standard. On n/a that is, dont have a clue whether the same applies to turbo's though?
    #29
  31. ricko
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    ricko Member

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  32. ricko
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    ricko Member

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    [Sep 12, 2010]
    I BLOODY DID IT:p i can now add computer skills to my c.v
    #31
  33. Gops
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    Gops 6th gear @7000rpm

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    [Sep 12, 2010]
    "fluent with microsoft word, excel and an expert in paint":p

    Looks good welly, had a test drive yet?
    #32
  34. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 12, 2010]
    how flat was your head flange on the one pictured?
    #33
  35. ricko
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    ricko Member

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    [Sep 12, 2010]
    the head flange was fine but i did have to skim the turbo flange. gops this is my engine bay not whelly's had it all in stalled for abit now
    #34
  36. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 12, 2010]
    i know its your engin ebay not his mate.. his manifold is sat here hanging on one of my heads on the shelf ;)
    #35
  37. ricko
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    ricko Member

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    [Sep 12, 2010]
    this is getting confusing lol. i know you didn't think it was whelly's. the fella before you called gops said " it looks good whelly, had a test drive yet"
    #36
  38. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 12, 2010]
    lol - very confused. (but I usually am)
    #37
  39. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 12, 2010]
    how you have'nt melted any pipes yet is staggering..
    #38
  40. s3_kev
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    s3_kev Stage2'd!!!!!!

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    [Sep 12, 2010]
    lol this has been a funny read since you joind in hahaha
    #39
  41. Welly
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    Welly VX220 SC Driver :)

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    [Sep 14, 2010]
    LOL, WTF is 'Whelly'? lol

    Anyway, some issues have come to light with this - 5mm warp on the manifold flange makes this manifold unsuitable sadly.

    I will be getting in touch with XS and having a chat about it, see what can be done.

    Turns out the pipes are stainless steel, and very well made. The flange however appears to be cast, and is magnetic making it clear that whatever material it is, it isn't stainless steel.
    #40

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