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APR Exhaust Manifold

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In order for the larger Garrett GTX2867R Turbocharger to mate to the factory head found on the Golf R’s 2.0T FSI Engine, APR was tasked with creating an exhaust manifold capable of supporting excessively high exhaust gas temperatures for long periods of time. Enter the APR Inconel Manifold. APR’s exhaust manifolds are known around the world for several highly sought after properties not completely shared by any other design in the market. Runner Lengths Many manifold manufacturers are after 1 thing: Equal exhaust runner lengths. The theory behind equal runner lengths is the exhaust pulses from each cylinder will arrive at the collection point, one after each other, without the pulses colliding. This will aid in power deliver and turbocharger spool compared to a traditional log style manifold or one w/o equal length runners. Typical stainless steel equal runner length manifolds have long twists and turns in order to achieve this, but they do so at the cost of strength and design quality. It’s a low-tech old school method designed to look pretty and get the pulses in line. The thin tubing with multiple weld points has a potential to crack over time, and the thin tubing walls create an undesirably loud exhaust that’s simply unacceptable for most daily driven applications. Creating one of these manifolds is quick for any skilled exhaust shop. On low volume products, it’s often an attractive product due to the time and costs involved in creating one, but given each exhaust is only as good as the person welding, and their mood during that days work, problems can arise and may only rear their head when it’s too late. The APR Exhaust manifold is able to achieve the same equal runner length properties as the other low-tech methods by varying the lengths of each runner. The runner lengths will be dictated some degree due to packaging constraints, but APR’s 3D modeling and computational fluid dynamics software allows our engineers to adjust the length of each runner, adding length where necessary, to ensure all exhaust pulses arrive one after each other without colliding at the collection point. The Inconel material has excellent heat retention characteristics that work to enhance turbo response by keeping exhaust velocities high. The order the pulses arrive differ from that of an equal length runner, but the outcome is enhanced by the properties of the material used. Strength APR’s exhaust manifold is made from Inconel 625, which is a very high temperature nickel-chromium-based superalloy designed to withstand extreme temperature changes without expanding, contracting, melting or cracking under stress. This material is very expensive material and is difficult to machine and at the inception of our first 1.8T turbocharger system, was upwards of $10,000 for a single Inconel manifold from VW Sport. APR has gone a step further by using an investment cast design rather than a sand-casting process. This expensive process results in smoother finishes and very tight tolerances to ensure each manifold fits properly. Each manifold is cast in the USA and machined in house using one of APR’s CNC machines to finalize all mounting surfaces. Quality control is very important given the labor and headaches one would experience with a failed manifold, so each manifold is inspected before and after machining. Never worrying about a cracked exhaust manifold is something an APR customer confidently feels every time they drive their vehicle. So to recap, here are some of the benefits of the APR Manifold Design: -Inconel 625 Material -High EGT Resistance -Low Growth/Contraction Under Heat -Guaranteed Not To Crack (Lifetime Warranty) -Exhaust Pulse Tuned Runner Lengths -Excellent Heat Retention Properties for High Exhaust Velocity -Low Noise Output -High Tolerances Investment Casting -High Precision CNC Machining In House -Repeatable Manufacturing Methods -Strict Quality Control -Made in the USA Next up we’ll look into a little more of the plumbing involved to route all air into and out of the turbocharger.

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APR, Exhaust, Manifold

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APR Tuned

Phone: (800) 680-7921 Local Phone: +1 (334) 502-5181 Fax: (334) 502-5180 Address: APR LLC, 4800 US HWY 280 West, Opelika, AL 36801

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Notice: Products that affect emissions and do not carry a California Air Resources Board Executive Order are not for sale in California, USA. While we try to keep everything current, APR LLC is not responsible for errors in pricing on this web site. All prices are in USD and are applicable to the United States of America only.
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