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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

    s3dave TFSI Hybrid
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    it can still be stainless steel and magnetic....430 grade
     
  2. ricko

    ricko Member

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    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
     
  3. S3 Paul

    S3 Paul Well-Known Member
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    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.
     
  4. Welly

    Welly VX220 SC Driver :)

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    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.
     
  5. Madeley

    Madeley Member
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    Tool steel gives a very weak weld, it may just be Bright mild steel.
     
  6. badger5

    badger5 www.badger5.co.uk
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    tool steel? cough.... chewed from a girder plate with blunt instruments more like - lol
     
  7. Speedy Steve

    Speedy Steve Active Member

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    so its a bitch to fit in place without stripping half the engine. I can see the 034 calling!
     
  8. Welly

    Welly VX220 SC Driver :)

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    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.
     
  9. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp?

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  10. Welly

    Welly VX220 SC Driver :)

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    A potential manufacturing defect. To review an item only seeing one example of it is a bit presumptuous....
     
  11. Welly

    Welly VX220 SC Driver :)

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    I can feel the love dude....
     
  12. Welly

    Welly VX220 SC Driver :)

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    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....
     
  13. Chlippo

    Chlippo Member

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    updates?

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

    s3gazz Well-Known Member

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    ill be getting one of these i can see when i start on the engine next year
     
  15. Chlippo

    Chlippo Member

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    i will probably get one very soon too and get it installed on christmas...but since welly was testing..im waiting :D
     
  16. badger5

    badger5 www.badger5.co.uk
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    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
     
  17. badger5

    badger5 www.badger5.co.uk
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    [​IMG]

    tsr's new mani pictures, interesting to compare.
    quality of welding much better, and looks like larger pipework..
     
  18. Welly

    Welly VX220 SC Driver :)

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    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.
     
  19. Chlippo

    Chlippo Member

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    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?
     
    #59 Chlippo, Nov 7, 2010
    Last edited: Nov 7, 2010
  20. badger5

    badger5 www.badger5.co.uk
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    ask tsr?
    ~£600 i heard, best to check with them
     
  21. Chlippo

    Chlippo Member

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    lol i did but didnt get a reply yet so i said maybe ask here :D
     
  22. Welly

    Welly VX220 SC Driver :)

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    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.....
     
  23. Welly

    Welly VX220 SC Driver :)

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    Is this going to be a 'here we go again' thread? lol....
     
  24. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Sex mate, sex, lmao.

    Whats the difference between the two manifolds welly? Also have they gave a idea on price?
     
  25. Welly

    Welly VX220 SC Driver :)

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    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.
     
  26. superkarl

    superkarl MAN OF STEEL

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    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?
     
  27. s3 Hoggy

    s3 Hoggy Whats going on???

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    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!
     
  28. Dani_B19

    Dani_B19 Audi-sports own special child.

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    No mate, the two new one's you've just took delivery of!
     
  29. Speedy Steve

    Speedy Steve Active Member

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    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
     
  30. aragorn

    aragorn "Stick a V8 in it!"
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    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.
     
  31. Welly

    Welly VX220 SC Driver :)

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    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.
     
    #71 Welly, Jan 12, 2011
    Last edited: Jan 12, 2011
  32. Welly

    Welly VX220 SC Driver :)

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    Not much to be honest dude, they are next to identical...
     
  33. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Ooh, so why they sent you mate, they just slightly different designs/fitting?

    Any news on the DP front too welly?
     
  34. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    I agree with hoggy, cheers dude!

    Ps anyone else still laugh at the dp abreviation? :laugh:
     
  35. Welly

    Welly VX220 SC Driver :)

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    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.
     
  36. Welly

    Welly VX220 SC Driver :)

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    :slap:

    :lmfao:
     
  37. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Lmao, yup :).

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

    s3dave TFSI Hybrid
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    321 up to 900c 321-H up to 1150c
     
  39. Welly

    Welly VX220 SC Driver :)

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    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.
     
  40. Welly

    Welly VX220 SC Driver :)

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    And, hopefully WMI will be fitted at the same time as installation....
     

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