Pics of my new exhaust

[gldgti]

Made this for the Cabriolet today - thought I would share because its perrrty :-)

I didnt make a new downpipe, I made a 2" mandrel bend DP when I did the engine swap, which seems good enough with the gt-15 (which is pretty small!) but with the new exhaust spool up is WAY faster than with the stock exhaust and performance is up aswell.

Its also quieter than it was before....







Made a 3" tip, by flaring the 2.5" pipe out to the ID of a 3" sleeve over the end, and TIG fused the end together.

[Smokey Eddy]

Nice welds dude

[bajacalal]

I like it.

What kind of muffler is that? I wonder if I can get one here...

[gldgti]

The muffler I got on ebay, but my best guess is that its a mass produced chinese one - very nicely made though and well polished  I'm sure you could get them over there. It cost be $89AUD including shipping.

Its all stainless, straight through, 10"wide x4" high x12" long, straight through, glass pack. The offset really helps on a mk1! I only had to kink the tailpipe off at about 4 degrees to make it out of the gap in the bumper.

[danster]

That looks good. The mk1 platform needs that kink to clear the gear shifter so has a bit of extra fabrication work involved.

As the thread is now moved out of the IDI section I will post my setup for my TDI in case it is useful and gives some ideas on what could be done.
Fortunately the Corrado does not have a clearance issue around the gear shifter mechanism, and can therefore use a straight pipe.
The existing petrol engine exhaust fitted to my car was an aftermarket 2.25" stainless system with a huge transverse silencer under the rear seats. This was cut out and the existing tunnel pipe was flipped and repositioned. I then bought 1 metre of stainless pipe and was able to make the de-cat pipe to link the system to the modified front downpipe which now utilise a 3 bolt flange for ease of fitting and removal, and then the short off-cut was used to link the existing centre pipe to the over axle part, This allowed me to retain the original straight through back box and tailpipe.
I wanted my exhaust note to have a bit more bark to it, so got the white dude on the case.


He got a bit tired with all the pipe measuring and cutting.


Then he had a quick snooze to recharge.


Ready for the welding. Woofer did a good job, and even managed to tig an old 50pence piece onto the EGR take off to blank it. The Queen is now well funky in her jubilee year as she looks to have an afro!  


I am quite pleased with the results.

[libbydiesel]

Nice work Gldgti.  Those welds look really good.  TIG?

Since danster started the free-for-all I figured I'd post a couple exhaust systems.

This first one is for a VNT15 fitted to a '79 rabbit.  All of this exhaust except the flex section is recycled tubing.  A friend does satellite dish installations and these were bits of brackets.  He was taking a trailer load to the metal recyclers and stopped by my place on the way.  I relieved him of a good amount of tubing.  The front downpipe is 2".  The rest is 2-3/8".  Straight pipe, no muffler.  It's louder than a new car, but quieter than a Dodge Cummins.



The next one is for an AAZ in a vanagon.  Quite a simple and effective exhaust.  The pipe goes into a Dynomax muffler that's not shown.  I'm in the process of doing this conversion and may well fire it up today, but since it hasn't run yet, I can't comment on the sound.

[CrazyAndy]

Theman53 built me this:



Gonna get the rest welded up by a local muffler shop as I can't weld for dirt.

[gldgti]

Thanks libbydiesel - yes, its almost all TIG, with a few bits of stainless pulse MIG (larger welds where I welded the mounts to the muffler and stuff).

some of those downpipes look great :-)

The hardest part was that I was using a hoist in one workshop, but I didnt have a welder there.... the welder was in another workshop about 25m walk away..... So I had to fit the pipes up, carefully mark the joints, take it apart, walk to the other workshop, tack it together, walk back, check, etc etc etc.

Got a lot of exercise!

[libbydiesel]

some of those downpipes look great :-)

I don't think you were talking about my recycled satellite dish mount exhaust which 'has a lot of character'.     On the upside, tho, it cost all of $25 for all the materials and it's very beefy. 

Also, the AAZ vanagon exhaust I showed is the entire exhaust aside from the muffler.  Very short exhaust and remarkably easy compared to the front engined cars.

[hillfolk'r]

them tig welds r sweet..makes mine look like i let a blind homeless dude weld mine
i got a mig,which is a glorified molten metal glue gun..
and of course im stupid.i used 2.25 and a glasspack on my 91
heres most of the section from the dp to over the axle,and the glasspack with the tip welded directly to it...i fitted the front half,then placed the muffler where i wanted it,and made up the difference in the middle which is not shown yet...mines an na,and i didnt care if its oversized cause im just goin for looks on this car...i wont wanna hurt performance but its not like itll gimme 100hp either.....i cut off the orig hangars from the old pipe and used them over
the pipe from summit is pretty reasonable,but heres  a tip..only order 4 foot sections or theres an oversize charge that will cost 50% of the pipe
the system i built pictured here cost 90
1 12" glasspack
2- 4' sticks of pipe
2- u bends
1- ss band clamp
oops i got an adapter at advance to step up to the 2.25 stuff and welded it on the dp and a crappy us clamp for at the back muffler cause i shoulda ordered 2 from summit.oh well.at least when i mess up ill tell ya

[gldgti]

MIG is great for mild steel exhaust work, but TIG is much nicer for stainless.

I really do like the recycling ethic going on - I kinda feel like I pulled out almost all of the stops making the cabrio exhaust.

My company makes stainless expansion joints, so our stainless supply prices are great. All up it cost me $210 in just the raw parts (flanges, piping and muffler). But, I'm very lucky to be in this position.

(I got a price on regular mild steel tube, it was MORE than the stainless price!!!)

[R.O.R-2.0]

I like it.

What kind of muffler is that? I wonder if I can get one here...

looks ALOT like a magnaflow..

i wouldnt run any muffler i could not see thru..

moroso spiral flow mufflers also work great on these engines..

ask 745 turbogreasel about them..

[hillfolk'r]

Sootys exhaust is loud,with a wicked rap to it.
it scares the honda kids,which was my point
i wanna say the 12" summit glasspack was g good bang for the buck
well,about 20$ worth
thats a sweet deal on the ss stuff you get man,im jelly lol
If ya got a turbo and are reading this thread trying to"shop" mufflers i dont see why you are asking ...none needed:) but ya prob want at leas t a 2.25 diameter mandrel bent setup..for the nutty guys, a 3" dp fitsi had one on the 79 and same thing,summits bends and some playtime with the welder
its really not that hard to do you just want good tools to be able to cut stuff easy.why waste all day with a worn out hand hacksaw thas no fun

[R.O.R-2.0]

totally...

there is no need for a muffler when you have one hanging off your exhaust manifold..

the cool thing about "TURBO" mufflers, is that they actually ADD POWER!

no, im not talking about corvair turbo spider mufflers...

mufflers are for N/A!!! lol..

[hillfolk'r]

Na dont need no mooflers
http://youtu.be/nl3iF7CgyJY