Example #3: APR Exhausts & Patents (Where’s the RSC?)
Since the switch from Billy Boat in 2008, APR has been heavily promoting the use of RSC technology in their exhaust line. Heralded as a drone-free solution, APR is quick to promote their exhausts photos of expensive-looking mufflers as well as claims of prestigious association.
Many of you have seen this cutaway that APR has posted numerous times both online and in product literature. You can read all the claims that APR makes about this technology on various product pages, including my favorite, “RSC™ incorporates innovative technologies developed in conjunction with NASA.”
http://i.imgur.com/SK8Q1Ba.jpg
http://i.imgur.com/gcv7FRc.png
Corsa’s patent for RSC technology is very specific, with several illustrations of muffler designs as well as explanations for how the RSC works.
Corsa RSC patent
http://i.imgur.com/IVeg1pw.png
http://i.imgur.com/gxpw1i0l.png
http://i.imgur.com/TuLIYxrl.png
http://i.imgur.com/zUhj6uLl.png
http://i.imgur.com/tZg7T3Kl.png
http://i.imgur.com/sBNwuKYl.png
http://i.imgur.com/uHnTtwSl.png
Now unfortunately, I have not found this technology in APR’s exhausts. It is questionable whether or not it has ever been present in an APR exhaust. Has APR been aware of this? Yes.
If APR is not putting RSC in the exhausts marketed as RSC, what is actually in these APR exhausts? From what I’ve seen and have been told by people investigating this issue, most of the mufflers are either standard perforated core mufflers with inadequate fiberglass packing, short quarter wave resonators which are sized for frequency ranges beyond that of human hearing and poorly constructed Helmholtz resonators. There are also instances where there was a muffler casing welded onto a straight pipe to give the appearance of an muffler without any of the functionality!
I’ve been provided photos of three APR exhaust platforms, VW Golf R, Audi B8 A4 & Audi B8 S4. The pictures speak for themselves. All cutaways are shown with exactly what was in the muffler. Nothing has been added or removed. Also, I did not personally take any of these photos.
VW Golf R
The first muffler in the system is a standard perforated core muffler. As you can see, APR markets it as RSC technology. There is no RSC technology. The muffler internals are poorly constructed out of non-304 stainless (409 & 439). The fiberglass packing is poorly arranged with minimal packing and much of it left in the bags it was packaged in.
http://i.imgur.com/xoFAHzm.jpg
To give you an idea of how dense the fiberglass packing should be, here is a cutaway of a megan exhaust (bargain brand) muffler.
http://www.meganracing.com/uploadimage/dpage/3172011_161538.JPG
The second muffler in the Golf R system is even more shocking as the can is essentially hollow. The cap on the outlet is the quarter wave resonator, but the length of the resonance tube is too shore to provide any sound cancellation beits within meaningful frequency ranges.
http://i.imgur.com/Ma76KGU.jpg
Nevertheless, look back at the original APR RSC cutaway as well as the RSC patent docs… no RSC here.
As posted earlier, Arin defended the exorbitant cost ($2275) of this system by claiming “Here’s what a typical RSC system looks like… The Golf R is many generations newer and far more complex. Welding this is not easy and the price unfortunately reflects that.” To me, that rear can looks less complex and easier to weld than an actual RSC muffler.
http://i.imgur.com/kVULfFD.jpg
Note: the TTRS exhaust is essentially two of the rear Golf R “mufflers”.
Audi B8 A4
This is the center muffler on the B8 A4 “RSC” exhaust. The front resonator is a standard perforated core resonator (No RSC). The center muffler also does not contain RSC. What you see instead is a Helmholtz style resonator (hole in pipe venting to an empty muffler chamber) as well as a small quarter wave resonator. Again, there is no RSC, but it is labeled as such by APR as having the RSC design. The rear section is also said to not contain RSC, but that will have to be verified by photos.
http://i.imgur.com/jmZIpZW.png
APR also makes a stink about this B8 A4 exhaust having smooth bends and transitions. As you can clearly see from the muffler cutaway, the bends and transitions are anything but smooth.
http://i.imgur.com/xJ3Wxtu.jpg
http://i.imgur.com/YqNZeVt.jpg
Update 11-18-2014, B8 A4 rear muffler photo
http://i.imgur.com/EWEXTyN.jpg
Perhaps they didn’t bother with the “golf ball test” because of the gaping hole in the piping through the muffler?
Audi B8 S4
The B8 S4 system consists of two extremely long perforated core resonators (Not RSC) which dump into a center resonator which hasn’t been photographed yet. I’m told that it isn’t RSC but am awaiting photographs to confirm it. The rear two mufflers are found to be merely straight pipes with no perforations or cutouts (Not RSC, not a muffler). Now the exhaust that was cut open has a 2010 build date. From a more recent thread on audizine, I see that they added the same tiny quarter wave resonator as well as the cutout to make it into a Helmholtz-style resonator. You can also see the issues with the quality of construction in the Audizine link.
The pictures of the double perforated core resonators are from a west coast car with 15k miles on it after one year. The piping throughout is rusted and the welds have failed.
http://i.imgur.com/4IIkl17.png
The following are from a different B8 S4. As indicated by the owner, the muffler’s welds failed and when cut open, he discovered nothing but a straight pipe without perforations or any other features of a muffler.
http://i.imgur.com/uFotIax.png
http://i.imgur.com/yr6tuHe.png
Nevertheless, with both the original straight pipe or the later quarter wave / Helmholtz addition to the rear mufflers, both designs are not RSC.
MK6 GTI
http://i.imgur.com/TRubo0n.jpg
Just another modified design of the quarter wave / helmholtz resonator. Instead of having the T branch off on the pipe inside the muffler, the “T” is external and still dumps into the empty muffler casing. How many golf balls were stuck in this muffler when performing the “golf ball test”?
Miscellaneous
More photos / cutaways may be provided in the future.
There are long wait times in getting any APR exhaust product warrantied.
One customer indicated to me that when he called Corsa, they responded with: “Why would we warranty a product we were never paid for?”
After last week’s SEMA event, several attendees who spoke with Corsa indicated that they’re looking to part ways with APR soon. If anything, Corsa’s product sheet reinforced that idea.
Since the only functional designs of noise reduction in the APR exhaust systems are quarter wave and Helmholtz resonators, I found it amusing what APR had to say when questioned about RSC vs Helmholtz (what AWE markets in their exhausts)
http://i.imgur.com/F2ksQx2.png
Thoughts and conclusions about APR exhausts:
----There has been a reduction in quality of the materials used (from T304L to various grades of 400 stainless)
----Exhausts were falsely advertised as containing the patented RSC design.
----Pricing has increased while quality and material selection have become worse
----APR claims a lifetime warranty but customers have been having issues getting exhausts warrantied both through APR & Corsa.
----This may present serious legal issues for APR as they sold these exhausts with false claims.
----I’m sure NASA does not approve of their name being used in APR’s marketing literature.