who we are exhaust systems development

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HIGH PERFORMANCE EXHAUST SYSTEMS
Welding facility
R&D Department
WHO WE ARE
Supersprint originated in 1955 and from the very beginning our
goals were to always offer the highest quality materials, superior
finish, and an unmatched product lineup with a keen focus on
researching, designing, and supplying the best performing exhaust
components worldwide.
Our website (www.Supersprint.com) includes detailed information on
every step of our production process from our independent design
to testing on our AWD MAHA dynamometer.
All Supersprint components meet or exceed the strict European
TUV requirements.
EXHAUST SYSTEMS DEVELOPMENT
For the exhaust for both the Elise/Exige and Evora models we
followed our usual “modus operandi”.
At our R&D facility in Mantova, Italy, the cars were tested in
stock configuration on our MAHA AWD dyno, one of the most
accurate dynamometers available.
Various runs were performed to provide accurate baseline
measurements including horsepower and torque. Next, the
vehicle was tested for sound levels, both inside and outside the
car, during idle and while under power. After all of the data is
collected our real job began...
An Elise Supercharged
“Type 25” on our MAHA
Dyno
An Evora ready for dyno
testing.
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HIGH PERFORMANCE EXHAUST SYSTEMS
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Underside view of the
Evora exhaust system
Welding of a primary pipe
and the flange of the Evora
header
We started by analyzing the available space under the chassis for
new components. Then, consideration was given to power, revs,
bore/stroke in order to choose the perfect combination of component sizing for the initial prototype.
Aesthetics were also analyzed at that time by examining the rear
bumper to select the perfect tip shape and size. The first prototype system was then designed and assembled in our facility utilizing
CAD software, CNC machines but above all, the expert hands of our
technicians.
Exhaust pipes
mandrel bending
CNC machines in our
facilities
As the first elements of the exhaust system were completed they
were immediately tested for flow and installed on the vehicle for
verification of performance gains via additional dynamometer runs.
Complex manifold designs often undergo multiple different
configurations of primary/secondary pipe diameters and lengths in
order to ensure optimal final results.
Watch the videos of the dyno runs on our website!
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HIGH PERFORMANCE EXHAUST SYSTEMS
Evora manifold
details
Exige/Elise
manifold detail
All the components are manufactured from high grade stainless
steel AISI 304. Even the smallest details, such as attachment
hardware, weld quality, and component joints are carefully evaluated
to avoid potential failure at critical locations.
The headers are completely designed and manufactured in-house
of 304 stainless steel. Piping thickness is generally 1.5mm and
all piping is mandrel bent for optimal performance. Connections
between piping sections are either TIG or MIG welded to ensure the
highest quality seal and strength and all original 02/EGT sensor
locations are retained to avoid any ECU anomalies.
Supersprint flanges are also made of stainless steel (varying
thickness between 7mm-12mm) and are CNC machined to
ensure perfect fitment while also being extremely resistant to
thermal stress.
Exige/Elise “Step-Design”
manifold detail
Evora “Racing” rear
exhaust detail
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HIGH PERFORMANCE EXHAUST SYSTEMS
Patent design
“Powerloop” rear exaust
Cut-away
rear exhaust
Supersprint mufflers are also produced inside our Mantova facility and
provide considerable weight savings over OEM mufflers due to the use of
specifically reduced thickness piping and sheeting.
Standard of all Supersprint mufflers is the “direct flow” design which is
indispensable for the optimal reduction of back pressure along the entire
exhaust system.
All internal and external piping of each muffler is 304 stainless as is the
external canister.
Attachment points and hardware are characterized by precision and
quality finish to ensure a perfect fit in OE locations.
Sound deadening is achieved via long lasting materials including an initial
winding of stainless steel wool followed by basalt wool for additional sound
absorption.
Our exhaust tips are also manufactured utilizing 304 stainless steel and
are available in over 30 different designs; each emblazoned with the Supersprint logo inscribed with a micro-percussion system.
OEM ceramic catalytic converter
HJS high-performance
metallic cat
The only Supersprint components not produced in our Mantova facility are the
metallic catalytic converters. Instead, we turn to HJS, a leader in motorsports and
performance catalytic converters, to manufacture all of our metallic cats.
These converters have a considerable amount of noble metals (rhodium, palladium,
platinum) which ensure their ability to withstand high temperatures over extended
periods of time. HJS is unmatched in the quality of their components which
guarantees we provide extremely durable, high quality, low polluting catalytic
converters with all of our performance systems.
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HIGH PERFORMANCE EXHAUST SYSTEMS
LOTUS EVORA 3.5i V6 (280 Cv) ‘09->
Complete exhaust system 100% Stainless steel Oversize Ø65mm
3 into 1 Headers - HJS metallic sports cat - Rear exhaust “Racing” OO 90mm
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HIGH PERFORMANCE EXHAUST SYSTEMS
LOTUS ELISE SC / EXIGE S (220Hp) ‘06–›
100% Stainless steel complete system Oversize Ø60mm
4 into 1 “Step-design” Manifold - HJS metallic sports cat - Rear exhaust “Road” OO 63 mm / “Racing” OO 80mm
“Step-design” Manifold
Rear exhaust “Racing”
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HIGH PERFORMANCE EXHAUST SYSTEMS
LOTUS EVORA 3.5i V6 (280 Cv) ‘09->
Nm
+26ma,x6gain
0 rpm
@680
OEM
Claimed data:
Horsepower 276 Hp @ 6400 rpm
Actual data:
Horsepower 274,7 Hp @ 6530 rpm
Torque 343,5 Nm @ 4920 rpm
HP
+2m6a,x7gain
@6800
rpm
Supersprint “Racing” system:
- Manifold R.+L. 441101
- Front kat 441102
- Rear exhaust “Racing” OO 90 441136
Actual data:
Horsepower 299,9 Hp @ 6810 rpm
Torque 360,0 Nm @ 5085 rpm
sepow
Max Hor
p
+25,2 H
er
ue
Max Torq
m
+16,5 N
LOTUS ELISE SC / EXIGE S (220Hp) ‘06–›
Nm
+15ma,x7gain
0 rpm
@620
OEM:
Claimed data:
Horsepower 220 Hp @ 7800 g/min
Torque 215 Nm @ 5500 g/min
Actual data:
Horsepower 226,6 Hp @ 8365 g/min
Torque 211,3 Nm @ 5295 g/min
Supersprint “Road” system:
- Manifold “step-design” 440401
- Front exhaust with metallic cat 440402
- Rear exhaust 440406
Actual data:
Horsepower 233,4 Hp @ 8400 rpm
Torque 222,3 Nm @ 5115 rpm
sepow
Max Hor
+6,8 Hp
er
ue
Max Torq
m
+11,0 N
HP
+1m2a,x5gain
@6200
rpm