[mike@x-ph.com]

When you hear Evolution Racewerks, one thing comes to mind: 100% made in the USA. They’re one of the few companies that still manufacture everything in-house, with no shortcuts. Their products stand out among overseas copies, built for customers who want the best quality. I’ve always wanted to visit their factory and finally got the chance. What a fantastic experience!

When we arrived, Fred, the owner, was right at the door. I’ve known him for 10 years; he’s a cool, respectful guy who’s very passionate and dedicated to his work. Evolution Racewerks is a reflection of him, no flashy marketing, no unnecessary hype. It’s all about precision and efficiency, a small but highly effective factory focused on producing the best possible products at the highest level.

What’s more impressive is that for a company as well-known and respected as they are, they spend zero time on social media or trying to show off. They let their products and customers speak for them.



The first phase of production is designing the prototype. This is where the initial concept takes shape, focusing on engineering, fitment, and improvements.



1-Buy a new car to start the design process as quickly as possible.
2-Get it on the lift for a detailed inspection.
3-Analyze BMW’s original design
4-Identify possible improvements in airflow, performance, sound, and/or reliability within the possible clearance available.
5-Use a jig to create multiple prototype designs



Phase 2: Building the Product / Prototype



1-Start with raw material: large stainless steel pipes.
2-Cut them into smaller pieces based on the design.
3-Check the fit on the jig to ensure accuracy.
4-Apply brushing for a clean, brushed finish.
5-Weld the pieces together
6-Test different prototypes to determine if more improvements are needed and which design offers the best fitment, reliability, and performance.
7-Deburr (clean up inside welds): This step is crucial to remove rough edges and excess material inside the pipes, ensuring smooth airflow and preventing turbulence that could impact performance.
8-If the customer requested a brushed finish, it’s done in-house. For a polished or thermal-coated finish, the product is sent to a local CA shop



Phase 3: Production



1-Build a small batch to begin initial production.
2-Beta testing: This is when vendors like us receive the product for real world testing, providing feedback and final thoughts.
3-Final approval: Once Fred is confident that he has built the best possible product, it launches on vendor websites and becomes available to everyone.



I had the pleasure of watching ER build an F90 downpipe from raw material to a finished product. Seeing the entire process firsthand was an incredible experience. Here is how it went



















More pictures from ER