Pushing New Design and Technology
We first looked at performance exhaust in the October 2023 edition. Since then, we have continued to design and develop new products, most specifically catalytic convertors. Our recent exhaust development process has taken a leap forward thanks to the use 3D scanning to map the Jaguar range.
Taking a detailed scan of the underside of the car enables us to map out every detail of the vehicles shape and undulations, allowing us to design and test fit items before they are made, saving time and materials when designing exhausts and ensuring that have the best flow path and fitment. Once mapped with a hand-held 3D scanner which has three cameras, the scan appears in real time on a computer next to us, so we are able check to see that every area has been scanned. The camera will then pick up over two million plus points of data which are overlayed like a topographic map onto the screen. Scans are automatically scaled to 0.2mm tolerance which make for a very detailed map with high points of data.
Once a completed scan is made then the design process can begin, starting with the fixed points that mount to the manifolds and vehicle centre section. We can import our pre mapped 300 cell CAT core and position this so that the path of least resistance is taken. We are then able to draw pipework with as direct routing as possible and utilising smoother bends and transitions. This is helped by one of the best features of the software, the ability to test the items before the dyno stage for predicted and accurate flow testing of the systems.
The next stage is to overlay a replica on our fabrication bench to the designed components, this then enables us to draw holders or jigs to keep the sections stable when we are welding the components together. These jigs are then 3D printed ready for each batch to be produced when needed. With the 3D printed jigs on the fabrication table the components are then laid out and tack welded in place, a roller is then used for consistent welds by turning the exhaust slowly and smoothly. Once welded up the finishing process for the pipes is then carried out by cleaning and polishing the metal sections.
Sport Cat Science
In a sports cat, the number and structure of the channels, also referred to as cells, are reduced. This optimises the air flow and reduces exhaust back pressure. The pipe diameter of your performance cat is also larger than with the standard car to improve cooling. While standard cats are often made of ceramic, performance cats are usually metal, with precious metal coatings. These are thus more robust and withstand the extreme performance we are working to achieve. They are produced through very elaborate processes. For instance, the metal films that form the channels are connected to each other in a vacuum furnace to ensure high strength and the intricate cell structures.
In addition to cleaning the exhaust gases, sports cats particularly feature improved performance with the added benefit of a sporty sound. Stainless-Steel cats consist of far fewer cells with thinner walls. Exhaust gas flow is drastically improved and significantly reduced back pressure by up to 85 % compared to standard catalytic converters. This also lowers the thermal load on the engine and turbocharger through the optimised design, ensuring an increase in performance and durability. With a sports cat, it is possible to achieve a better emission standard. Especially if you optimise your entire exhaust system. Our exhaust components are designed and built on site using the finest materials.
Key Features:
- High quality 304 Grade stainless
- Tig welded and purged for optimum flow
- Replaces restrictive OE catalytic converter
- 300 Cell Per Square Inch for better flow rate and MOT compliance
- Direct replacement for the original cat down pipe with clamps and slip joints
Our SR 300 cell Sports Cat replaces the more restrictive catalytic converter with a much free flowing, higher performance sports cat, this can unlock big potential power gains especially when combined with one of our tuning packages. Typically, standard catalytic convertors will have a somewhat restrictive 600 or 800 cell per square inch (CPSI) substrate.
Performance High Flow Cats (HFCs) improve air flow through the exhaust system whilst being able to pass MOT emissions tests, unlike a De-Cat and Test Pipes which do not pass emissions tests. With all sports cats, there is a possibility that HFCs will bring up an Engine Management Light, CEL Eliminators usually work but this is not always the case. We recommend getting the car remapped after fitting on 4.2ltr onwards vehicles to remove the light if the EML persists, however 4.0ltr models will require lambda extensions due to the inability to remap the ECU on older models.
An upgraded CAT is an essential part of our highest performing upgrade packages due to the need for increased flow at higher RPM however these are equally ideal for older models where the original CAT has broken down due to age or long term fuelling issues which has caused them to block the system (Something that we are seeing more and more of on pre-2010 cars as well as late 90’s vehicles where Jaguar replacement parts no longer exist).
300 Cell Sports CATS Model Range –
X351 – 5.0 Supercharged V8
X351 – 3.0 Supercharged V6
X350 – 4.2 Supercharged V8
X250 – 5.0 Supercharged V8
X250 – 4.2 Supercharged V8
X260 – 3.0 Supercharged V6
X260 – 2.0 Petrol Turbo
F-Type – 2.0 Petrol Turbo
F-Type – 3.0 Supercharged V6
F-Type – 5.0 Supercharged V8 RWD
F-Type – 5.0 Supercharged V8 AWD
F-Pace – 5.0 Supercharged V8
F-Pace – 3.0 Supercharged V6
F-Pace – 2.0 Petrol Turbo
XE – 3.0 Supercharged V6
XE – 2.0 Petrol Turbo
S-type R – 4.2 Supercharged V8
X150 – 4.2 Supercharged V8
X150 – 5.0 Supercharged V8
X100 – 4.0 Supercharged V8 Early
X100 – 4.0 Supercharged V8 Late
X100 – 4.2 Supercharged V8
X308 – 4.0 Supercharged V8
Contact us for more information,
