Ferrari 458 by Capristo Exhaust Systems - less weight, more power

(lifePR) ( Sundern, )
Introduced to the public in September 2009 at the International Automobile Fair (IAA) in Frankfurt, the Ferrari 458 Italia followed in the footsteps of the successful Ferrari F430. Powered by an 8-cylinder engine producing a copious 570hp, the 1380kg Italia reaches speeds of up to 325km/h.
For a basic price of 200.000 Euro, the tight suspension and an impressive 540 Nm of torque at 6000rpm offer sports car enthusiast that special Ferrari driving experience. Seven gears, a broad range of optional extras, and a comparatively modest fuel consumption of 13,3 liters per 100km round out the package.

Trimming down a supercar

As a specialist for luxury car exhaust systems, we at Capristo naturally asked ourselves how even a car like the Ferrari 458 Italia could be further improved. This mainly meant saving weight to achieve better overall performance. Additionally, we also focused on power recovery and the exhaust gas routing. This way of unleashing a car's full potential without changes to drivetrain, gearbox or engine management is our core expertise. In the end, we realized that the Ferrari 458 could do with a weight reduction as well as an improved exhaust gas routing, with added individual settings to produce an even more impressive engine noise.

Carbon fiber instead of plastic and metal

Following this strategy, we examined the Ferrari 458 more closely. The aim was to find parts that could be replaced with lighter materials without adversely affecting the mechanical properties of the body or the attached parts. From the first glance right through to a thorough inspection of the undercarriage and individual parts, our experts managed to find quite a few opportunities for trimming some fat. Obviously, changing the basic look of the Ferrari 458 Italia was out of the question.
After ascertaining which parts could make way for lighter alternatives, we followed up with comprehensive tests regarding exhaust gas routing and heat emission. Ultimately, we developed an exhaust system which will raise overall power by as much as 30hp while strongly reducing engine heat mainly by means of an improved exhaust gas routing.

After further deliberations, we concluded that the Ferrari's weight could be reduced by as much as 100kg, thus considerably improving weight/power characteristics. Additionally, the exhaust system was to be changed from the manifold right up to the tail pipe without noticeably changing the appearance of the car.

All non-structural parts of the Ferrari underwent materials testing. We quickly realized that in the interest of stability and durability could only be replaced with a lighter material if it was at least equally robust. The natural choice here were carbon fiber components, which combine lightness and rigidity.

On the visible body, we replaced the mirrors, door ledges, rear window end plate, the two front wings, hood lock casing, filler cap, diffusor, and rear fog light casings. Parts of the engine compartment casing and the high pressure pump covers were also replaced with carbon parts. In accordance with our high standards, we paid utmost attention to leave all parts in their original shape, so as to reduce visual changes to a minimum. A welcome side-effect is the fact that the carbon parts used also fit every other Ferrari 458. The largest changed parts are the diffusor at the rear and the rear window end plate, which previously were made from plastic. Here, carbon with a gloss finish offers a fresh, classy look. As the diffusor is made completely from carbon fiber, which is unusual, the entire part weighs in at only two kilograms.

In contrast, the entire undercarriage of the Ferrari 458, which replaces the original plastic parts, sports a rugged, matt carbon look. The carbon underbody cover saves about seven kilograms while still fulfilling all the requirements of the original cover. Of course we guarantee the inclusion of standard suspension point to enable an easy exchange. Keyed with all other parts, the new underbody cover keeps full functionality intact. New carbon wheel house casings for all for wheels, also in matt, are another seven kilograms lighter than the original parts.

Less obvious at first and even second glance are the changes below the Ferrari 458's sporty looks. However, as usual, we still paid extensive attention to carefully outfitting the engine compartment and the trunk. The carbon trunk liner saves over six kilograms while still keeping all the functionality of the original fittings. Even more impressive is the engine compartment. Here, we concentrated on the upper part of the air filter housing. Not only was the airbox rebuilt in carbon fiber, we also increased the volume and optimized the airflow in conjunction with our changes to exhaust routing and manifold geometry, while retaining full compatibility of all connections. To complement the distinctive carbon look, you can install the Ferrari emblem in a specially made receptacle.

If you add up the effects of the carbon parts small and large and the new exhaust system, our optimization reduces the weight of the Ferrari 458 by almost 10% of the total weight. Those values basically equal the weight of a co-driver. Including the enhanced performance achieved by installing the new exhaust system, the weight-to-power ratio is now 2,19kg/hp compared to the original 2,42kg/hp, a result that obviously has a positive impact on performance and fuel consumption, while not affecting the original superior driveability in any way.

More performance, deeper sound, and efficient heat protection

Naturally, we did not stop at only making the Ferrari 458 lighter, but also aimed to develop an improved, performance-enhancing exhaust gas routing, while simultaneously reducing engine compartment heat, a goal we fully accomplished in lowering heat emissions by as much as 75 percent. From the manifold to the tail pipe, many parts of the exhaust systems were comprehensively overhauled.

As with our carbon parts, great attention was paid to compatibility in building the new valve-controlled exhaust system. The fan-shape manifold was designed 4in2in1 and naturally fits the original connections. The changed shape aides performance-supporting exhaust gas routing and accurate fit. The same perfect fit is demonstrated by the improved exhaust silencer made from high-grade 1.4828 stainless steel. For both those parts, we developed a new heat protection system with markedly improved performance in continuous operation, which is also responsible for the above-mentioned reduction in engine heat emissions. The new exhaust system also features a 2x200 cell catalytic converter. The Exhaust system is joined to the factory-provided programmable valve control, which can be complemented with a remote-control manual valve control. With this, the sound parameters of the exhaust systems can be individually set at a moment's notice. All modified parts are road legal and TÜV-certified. Overall, the changes to the exhaust system add more than 5% to the original performance.

The result: careful changes, massive improvements

With the Ferrari 458, our aim was to turn an already powerful sports car into a performance-enhanced powerhouse with optimized weight through a few careful and well-placed modifications, foregoing everything that could adversely affect electronic control, engine management or technology. The stated aim of measurable weight reduction is achieved by the sensible use of carbon fiber parts, while an improved airbox and an optimized exhaust system improve performance.

Our expertise enables us to achieve such a performance increase without endangering the integrity of the vehicle. All conversion parts are built to smoothly replace original parts, so that every single Capristo carbon part and every component of the exhaust system can be fitted to any Ferrari 458.

From design to execution, paramount attention was paid to the use of genuine carbon parts. While many other companies pass of glass fiber reinforced resin as carbon, we insist on using only pure carbon fiber with all its outstanding characteristics. This way, less weight and more exhaust system efficiency make the modified Ferrari 458 what it is: A brilliant car with real, individual class.
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