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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. s3dave
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    s3dave TFSI Hybrid

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    [Sep 14, 2010]
    it can still be stainless steel and magnetic....430 grade
    #41
  2. ricko
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    ricko Member

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    [Sep 14, 2010]
    sorry whelly i mean welly, i think if you move fast enough the heat cann't stay they long enough to melt anything. my flange is ok so the doctor say's lol. But if can help in any way just let us know whaley
    #42
  3. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Sep 14, 2010]
    I had to skim a tig art turbo flange for a company before as it flexed when welded.
    Im sure the tig art ones used to come loose on the turbo to mani flange and blow the gasket out on a regular basis.
    I think some people even took to tacking the nuts to the manifold.But then the studs stretched.
    #43
  4. Welly
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    Welly VX220 SC Driver :)

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    [Sep 14, 2010]
    Maybe, I'm pretty sure it isn't however - it's not high enough quality IMO. Looks to be something along the lines of tool steel.
    #44
  5. Madeley
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    Madeley Member VCDS Map User

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    [Sep 14, 2010]
    Tool steel gives a very weak weld, it may just be Bright mild steel.
    #45
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 14, 2010]
    tool steel? cough.... chewed from a girder plate with blunt instruments more like - lol
    #46
  7. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 14, 2010]
    so its a bitch to fit in place without stripping half the engine. I can see the 034 calling!
    #47
  8. Welly
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    Welly VX220 SC Driver :)

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    [Sep 14, 2010]
    Ummm, not quite dude. I mean the example I have is beyond fitting due to bad workmanship. I think they are going to send another one - hopefully it will be better.
    #48
  9. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Sep 14, 2010]
    How will the new one be different?
    #49
  10. Welly
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    Welly VX220 SC Driver :)

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    [Sep 14, 2010]
    A potential manufacturing defect. To review an item only seeing one example of it is a bit presumptuous....
    #50
  11. Welly
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    Welly VX220 SC Driver :)

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    [Sep 14, 2010]
    I can feel the love dude....
    #51
  12. Welly
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    Welly VX220 SC Driver :)

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    [Sep 17, 2010]
    OK - XS Power are sending me out another manifold, same spec as the previous. As I said before, I suspect that, based on the fact an ASN member is using one, the one I got may just of been a bad one of a good bunch.

    Hopefully, I can get it installed at the same time as the hybrid and we can see what's what....
    #52
  13. Chlippo
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    Chlippo Member

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    [Nov 6, 2010]
    updates?

    i am planning to get their dpipe and the manifold, just waiting your conclusion :D
    #53
  14. s3gazz
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    s3gazz Active Member

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    [Nov 6, 2010]
    ill be getting one of these i can see when i start on the engine next year
    #54
  15. Chlippo
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    Chlippo Member

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    [Nov 6, 2010]
    i will probably get one very soon too and get it installed on christmas...but since welly was testing..im waiting :D
    #55
  16. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 6, 2010]
    wellys running an 034 manifold now, and i doubt he will be volunteering for more manifolds to fit.... Someone else's turn to be guinee pig perhaps
    #56
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 6, 2010]
    [​IMG]

    tsr's new mani pictures, interesting to compare.
    quality of welding much better, and looks like larger pipework..
    #57
  18. Welly
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    Welly VX220 SC Driver :)

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    [Nov 6, 2010]
    I'm still waiting on some data back from the manufacturers guys, so I'm holding on about a verdict as yet....

    A point to note is that the XS Power tubular will not fit using OEM bolts. The TSR one does, and will it would appear.
    #58
  19. Chlippo
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    Chlippo Member

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    [Nov 7, 2010]
    ok maybe ill do it myself..and fabricate some special bolts to make it fit, and see how it goes with their dwpipe

    what is the price on tsr's ones?
    Last edited: Nov 7, 2010
    #59
  20. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 7, 2010]
    ask tsr?
    ~£600 i heard, best to check with them
    #60
  21. Chlippo
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    Chlippo Member

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    [Nov 7, 2010]
    lol i did but didnt get a reply yet so i said maybe ask here :D
    #61
  22. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Well, some time has passed, and there is more on this...

    As Bill said, I did indeed fit the 034 motorsport manifold... With excellent power results. Approx 30 BHP on a hybrid installation was the gain, with the engine holding torque much, much better.

    Here is a comparison graph:

    [​IMG]

    Sadly, as many of you will be aware from the ongoing saga, the 034 manifold cracked after 1000 miles, and has led to me refitting the standard OEM manifold with a ported collector....

    And that's where we are today....

    Anyway.... the manifold to head flange on the previous XS Power manifold was a little suspect, and despite me managing to get it ground flat, the manifold was still not really suitable to be fitted. Sadly. It came out of the box approx 6mm out of square, and the holes weren't in the right places to fit the head.

    It had the makings of a very good product with a collector which had the potential to flow very well indeed.

    Anyway, I wrote up a long load of drivel about how it wasn't suitable for fitment for X, Y and Z reasons, sent this to XS Power for them to review and promptly shelved the idea.

    However, this has now come back into the game somewhat in my search for a replacement manifold for the 034. JBS are in the process of finalising their K04 manifold, however this won't be around until end of Feb at the earliest. And at £450 it won't be cheap.

    The other option I gave thought to was the TSR manifold. Nice, but far to pricey for me to justify.

    And then an email comes through saying that I have 2 K04 manifolds on their way to me from XS Power...

    Based on the previous one, I was a little concerned, however they have arrived on my doorstep today.

    And I am impressed.

    One of the manifolds has a very slight warp on the flange indeed, however it is minimal, and the gasket will take up the gap no problems I would think. Mock fitting will confirm or deny this.

    The second one's flange is spot on the money, flat, or as near as damn it.

    The other thing which is much better is the hole arrangement. I have used the 034 manifold I have here as a basis for comparison, and the holes on both manifolds appear to be drilled in exactly the right places to fit directly to the head.

    So, I am now planning to fit this, and see what's what. I'm not planning on fitting straight away, looking to mock fit over the weekend and see what is what before making a final decision (as it will cost me £100 to actually fit and test it - again!).

    Credit where credit is due though, what has been said has been taken on board and been resolved.

    Photos here:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Watch this space.....
    #62
  23. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Is this going to be a 'here we go again' thread? lol....
    #63
  24. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jan 12, 2011]
    Sex mate, sex, lmao.

    Whats the difference between the two manifolds welly? Also have they gave a idea on price?
    #64
  25. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Which 2 dude, old and revised?

    Build quality mainly.... and the fact it has the potential to fit mainly. Longevity still an unknown entity obviously, however, if fitted, this will be tested to the utmost as I do have the tendency to drive a little hard....

    Price retail is £285. XS Power are not selling them on ebay currently, but they were going for less than retail on there a few months back.
    #65
  26. superkarl
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    superkarl MAN OF STEEL

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    [Jan 12, 2011]
    Arent the bolts for the turbo-mani a pain in the ring to get to though?
    Do you take the head off, fit mani and turbo and slot all that in together?

    And lol, sorry for all these questions, did porting the standard mani collector make any difference at all?
    #66
  27. s3 Hoggy
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    s3 Hoggy Whats going on???

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    [Jan 12, 2011]
    Welly you are indeed a legend, I don't intend on doing the majority of work you post up on here but I still appreciate the amount of work you put in to help others out (with threads like this). Good luck with the installation hope all goes well!
    #67
  28. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jan 12, 2011]
    No mate, the two new one's you've just took delivery of!
    #68
  29. Speedy Steve
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    Speedy Steve Active Member

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    [Jan 12, 2011]
    I have a warming sensation. Could this be from my laptop or the excitement of a possible sorted XS manifold all looks a lot better
    #69
  30. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 12, 2011]
    What is the wall thickness on the pipe used?

    If its 1.5mm it simply wont last.

    If its nice and thick 2.5-3mm pipe of the correct grade (321) then you might have half a chance.
    #70
  31. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Not sure on that one mate to be honest, However, someone I have been in contact with has been using one for 9 months now without failure.

    EDIT: Also, it's claimed to be 321 grade SS.
    Last edited: Jan 12, 2011
    #71
  32. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Not much to be honest dude, they are next to identical...
    #72
  33. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jan 12, 2011]
    Ooh, so why they sent you mate, they just slightly different designs/fitting?

    Any news on the DP front too welly?
    #73
  34. Dane
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    Dane Faster than a V12 Q7

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    [Jan 12, 2011]
    I agree with hoggy, cheers dude!

    Ps anyone else still laugh at the dp abreviation? :laugh:
    #74
  35. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    Yeah, they are currently waiting on me. They have revised the downpipe to fit with the OEM kit and sent me a sample. The lambda boss was in the wrong place though, so I will drill it where it should be and send it back.

    Then they should be good to go.

    New revised one was a pukka fit, really impressed. The lambda boss let it down though. With that sorted, cushty.
    #75
  36. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    :slap:

    :lmfao:
    #76
  37. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jan 12, 2011]
    Lmao, yup :).

    Sound, looks like XS power may be getting a lot of business their way if all goes well.
    #77
  38. s3dave
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    s3dave TFSI Hybrid

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    [Jan 12, 2011]
    321 up to 900c 321-H up to 1150c
    #78
  39. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    That will be pretty close to tolerance then... Hmmmm.

    Although, to be fair, I am not running the boost I was with the 034 as it is more efficient to dial in more timing for extra power without the heat.

    Also, the additional flow ability of the manifold itself should knock EGTs down.
    #79
  40. Welly
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    Welly VX220 SC Driver :)

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    [Jan 12, 2011]
    And, hopefully WMI will be fitted at the same time as installation....
    #80

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