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Author Topic: homemade 2.5" DP  (Read 9737 times)

October 23, 2010, 08:29:42 pm

dankcorey22

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homemade 2.5" DP
« on: October 23, 2010, 08:29:42 pm »
How hard is it to make a 2.5" DP? I know people has done it, but im wondering what angles and bends they used.
Or what did they go by? The stock downpipe?

its on a 1.6td

Could someone tell me references to making one. i don't want to pay 300 for one.
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MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods
Reply #1October 23, 2010, 08:35:30 pm

gribur

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Re: homemade 2.5" DP
« Reply #1 on: October 23, 2010, 08:35:30 pm »
I have a 1.9td and am definitely interested in any info out there.  No way I can cough up that much cash either.  Someone please give out some info, you could save us all a ton of cash. cheers guys!
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Reply #2October 23, 2010, 08:54:48 pm

Vincent Waldon

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Re: homemade 2.5" DP
« Reply #2 on: October 23, 2010, 08:54:48 pm »
A mandrel-bent j-bend and away you go:

http://www.vwdiesel.net/forum/index.php?topic=14003.0
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Vince

Edmonton, Alberta, Canada
2001 silver TDI Jetta Malone Stage 1.5 , 2001 blue TDI Jetta SBIII 216s Malone Stage 3, 1970 Bay Window bus

Gone but not forgotten: 1969/1971 Beetles, 1969/1974 Westies, 1979 Rabbit, 1986 TD Jetta, 1992 gas Jetta, 1994 TD Jetta
Reply #3October 24, 2010, 01:38:33 am

KinseyJ

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Re: homemade 2.5" DP
« Reply #3 on: October 24, 2010, 01:38:33 am »
I think i spent about 75 buck for some mandrel bents online, my downpipe was a little bit more complicated cause i had a g60 intake manifold and i flipped my turbo and exhaust maifold upside down, so it came out on the other side and had to clear my rear motor mount. if you can get your hands on a wire feed welder and a metel chop saw you will be set. took me one evening to get mine all built. i would post pics but i'm not sure how. good luck
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91' jetta 1.6TD, G60 intake manifold, GTD injectors, FMIC, custom downpipe, 2.5" straitpipe exhaust, oversized pistons, fresh rebuild, running 10 psi. finally done!! 9 gruelling months of late nights in the garage.
Reply #4October 24, 2010, 02:34:09 am

Smokey Eddy

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Re: homemade 2.5" DP
« Reply #4 on: October 24, 2010, 02:34:09 am »
i used a 180 and a 90
cut up the 180 to make it work. dont remember exactly what angles but you can figure it out pretty easily. then the 90 is to direct it backwards.
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Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD
Reply #5October 24, 2010, 01:41:11 pm

dankcorey22

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Re: homemade 2.5" DP
« Reply #5 on: October 24, 2010, 01:41:11 pm »
i think the hardest part will be keeping clear of the shifting links or the transmission mount right?
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MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods
Reply #6October 24, 2010, 06:23:25 pm

81 vw pu

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Re: homemade 2.5" DP
« Reply #6 on: October 24, 2010, 06:23:25 pm »
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Reply #7October 24, 2010, 06:48:44 pm

dankcorey22

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Re: homemade 2.5" DP
« Reply #7 on: October 24, 2010, 06:48:44 pm »
Quote from: 81 vw pu on October 24, 2010, 06:23:25 pm
Here's a link for a mk1.

http://www.vwdiesel.net/forum/index.php?topic=19113.msg143382#msg143382


Thats exactly what i needed! thanks man!

I made my flange but i think i got some metal that was too thin:( after seeing what they used on theirs. I spent alot of time on it too. Wonder if i can buy just the flange already made to fit 2.5" pipe
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MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods
Reply #8October 24, 2010, 07:23:46 pm

theman53

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Re: homemade 2.5" DP
« Reply #8 on: October 24, 2010, 07:23:46 pm »
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Reply #9October 24, 2010, 10:09:30 pm

Smokey Eddy

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Re: homemade 2.5" DP
« Reply #9 on: October 24, 2010, 10:09:30 pm »
The hardest part for me was making it with enough clearance for when the engine torques the pipe doesn't hit the underside of the car.
its a tight squeeze with a power steering rack.
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Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD
Reply #10October 25, 2010, 09:33:35 am

dankcorey22

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Re: homemade 2.5" DP
« Reply #10 on: October 25, 2010, 09:33:35 am »
Lucas that the wrong one. im talking about the flange on the turbine housing.

And my car doesnt have power steering so im good with that!
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MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods
Reply #11October 25, 2010, 03:40:35 pm

theman53

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Re: homemade 2.5" DP
« Reply #11 on: October 25, 2010, 03:40:35 pm »
Turbo Outlet???
Scroll down in the link or click on VW on the side. They have what you need I am sure.
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Reply #12October 25, 2010, 07:00:05 pm

dankcorey22

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Re: homemade 2.5" DP
« Reply #12 on: October 25, 2010, 07:00:05 pm »
oh yeah the K03 outlet. I just didnt scroll down far enough. thats pretty cheap! and cheap!
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MY CARs-BLACK 99.5 Jetta TDI 5 speed 93,000- DC Stage 2 Clutch Kit 14Lb FW, Afe air intake box, 2.5" DP, 11mm IP, 2.5" stright piped, boost gauge, PP764, RC5 (WOW), 3-Bar, McNally EGT/Boost, 17/22, Race Pipe, EGR Cooler Delete, PD lift pump, R32 MAF housing,FMIC

1983 VW Jetta 1.6 turbo fuel mods
Reply #13October 26, 2010, 09:35:34 am

R.O.R-2.0

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Re: homemade 2.5" DP
« Reply #13 on: October 26, 2010, 09:35:34 am »
easiest way to build a downpipe on a mk1 car is to install a VNT on it, then there is only 2 90* bends needed, one directing the exhaust down, and one directing it back..

(lol  8))
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92 Jetta GLI - Black, 1.6D w/ GT2056V turbo..
86 GTI - 4 Door, Med Twilight Gray, Tow Machine..
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Turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster.
Reply #14October 26, 2010, 03:35:25 pm

regcheeseman

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Re: homemade 2.5" DP
« Reply #14 on: October 26, 2010, 03:35:25 pm »
Quote
easiest way to build a downpipe on a mk1 car is to install a VNT on it, then there is only 2 90* bends needed,

Where did you get the flange for the VNT?
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