Exhausts for a TD

[Bugsy_malone 666]

Ok so on my camper I have a 1.6TD engine, for the exhaust system because the engines a custom install I have 2" odd down pipe that then goes to a 3 bolt flange after 2.5 foot the same as you find on aircooled vans/beetles etc. The exhaust then goes to 2.5" pipe to an edelbrock silencer which makes it quieter, but still loud.

Recently the exhaust broke due to vibration so I welded it up good and solid and surprisingly it broke again today!

So I am wondering what standard golf exhausts are like for the 1.6td? turbo back up etc? I'm looking for something to make it quieter with good performance.

[bajacalal]

It's breaking because I think your exhaust needs to be more flexible between the engine downpipe and the rest of the exhaust. These engines wiggle and vibrate a lot. Techtonics Tuning offers a TD downpipe but it's incredibly expensive even without shipping to where you are, but you could probably build a similar setup on your own of have a local exhaust shop make one.

The stock exhaust isn't very good. It's quite restrictive although probably a lot quieter than what you're using.

I think these cars benefit a great deal from using a resonator, which is like an open chambered straight-though muffler, which slows down the exhaust a little and cuts back on some of the drone. The stock exhaust systems on the Golf/Jetta (and I think the van too) used a resonator. While not technically a resonator, I'm using the 2.5" Moroso spiral racing muffer, in front of a generic open ended muffler, and the addition of the Moroso unit really seemed to cut back on the drone while coasting or cruising, but it is still loud under acceleration. I think you would have the same results from any resonator of similar construction.

You might want to see this thread also:
http://www.vwdiesel.net/forum/index.php?topic=33051.0

[Bugsy_malone 666]

Well I been thinking about building a new system, I was thinking I'd like something made from stock parts but thought to help it breath maybe from a bigger engine. I have been looking at Landrover 2.5 Diesels, they come as turbo version and the pipework is pretty much all 2" end to end (maybe a little more like 2.25/2.5") and the system comprises of lots of pipe, a large chambered centre silencer then quite near the end a little straight through one.

I figured getting a system like that, its designed for a 2.5TD engine it will breath plenty for a 1.6TD! while it should also still make it quiet, I cant say anything is as loud as my van.

I'm also going to find an air box for my air filter to try to reduce induction noise and I think if I redesign one of the engine mounts I should be able to make the thing fine to drive!

[8v-of-fury]

A single muffler system should be plenty of muffling for a turbo diesel engine.

[Bugsy_malone 666]

You'd be surprised lol. I seriously want to make my thing lot quieter now with the way its been recently.

[spencebm]

I'm leaving the forum if another one of you guys starts another muffler thread! jk!  The turbo is the muffler!

[DCC]

It's breaking because I think your exhaust needs to be more flexible between the engine downpipe and the rest of the exhaust. These engines wiggle and vibrate a lot.

Exactly. Maybe you need to fit one of these:

[bajacalal]

A single muffler system should be plenty of muffling for a turbo diesel engine.

Have you actually tried it both ways? The addition of a pre-muffler resonator seems to make a considerable difference on these, and shouldn't be a huge compromise of power. Volkswagen used this system on all it's cars, going all the way up to the TDI and I think there's a reason for that. Driving a loud car can be fun for a while but it gets old really fast especially on long trips.

[8v-of-fury]

A single muffler system should be plenty of muffling for a turbo diesel engine.

Have you actually tried it both ways? The addition of a pre-muffler resonator seems to make a considerable difference on these, and shouldn't be a huge compromise of power. Volkswagen used this system on all it's cars, going all the way up to the TDI and I think there's a reason for that. Driving a loud car can be fun for a while but it gets old really fast especially on long trips.

I have three turbo diesels that are daily status in my driveway right now, all of them are down pipe only exhausts lol. k03, k14 and k24. K24 is the quietest.. if you pop the intake tubing off, the turbo almost isn't spinning at idle. The k03 on the other hand I swear is boosting a few pounds.

I agree that every moderate horsepower engine breathes through several mufflers and a 2.25-2.5" exhaust piping.. So is 3" straight piped necessary for our measly sub 200hp 4 cylinders? Absolutely not.. 2.25" a resonator and a normal diesel muffler will not restrict flow in any measurable amount for any of our daily power goals. Its all them rednecks thinking their 1.6's need 3" turbo back for any performance at all lol.

[R.O.R-2.0]

A single muffler system should be plenty of muffling for a turbo diesel engine.

Have you actually tried it both ways? The addition of a pre-muffler resonator seems to make a considerable difference on these, and shouldn't be a huge compromise of power. Volkswagen used this system on all it's cars, going all the way up to the TDI and I think there's a reason for that. Driving a loud car can be fun for a while but it gets old really fast especially on long trips.

I have three turbo diesels that are daily status in my driveway right now, all of them are down pipe only exhausts lol. k03, k14 and k24. K24 is the quietest.. if you pop the intake tubing off, the turbo almost isn't spinning at idle. The k03 on the other hand I swear is boosting a few pounds.

I agree that every moderate horsepower engine breathes through several mufflers and a 2.25-2.5" exhaust piping.. So is 3" straight piped necessary for our measly sub 200hp 4 cylinders? Absolutely not.. 2.25" a resonator and a normal diesel muffler will not restrict flow in any measurable amount for any of our daily power goals. Its all them rednecks thinking their 1.6's need 3" turbo back for any performance at all lol.

there is no such thing as too big of an exhaust tho..

bigger wont kill any performance in this case..

and bigger pipe will have less of a tendancy to rap/drone as well...

[Bugsy_malone 666]

I'm leaving the forum if another one of you guys starts another muffler thread! jk!  The turbo is the muffler!

No one is stopping you. The turbo is not the muffler, the muffler is the muffler. If you actually clock any mileage in a vehicle you appreciate how its nice to be able to talk to your passenger sat next to you or even think.


I did consider putting a flexi in, but also realised that mk1 version of my engine install, the system was actually mounted to the engine as you find it in a vanagon. So I may go down this route. I think maybe the engine rattles more than it used to, its been in there for 4 years and covered a good few thousand miles before it broke the first time, then this time it went in 500 odd miles.

I am not overly happy with my current setup so I am getting some mufflers as found on 90s Land Rover/Range rovers 4x4's, which have a main muffler and a small one near the end of the system. Theres lots of systems for them, but I am selecting parts from the 2.5TD as I figured with rangerovers being a premium 4x4 means they are quiet, without hurting performance too much, this coupled with the fact you'll end up with an exhaust system that breaths for 2.5 litres with only a 1.6l breathing through it. Equally being the UK landrover parts are generally a cheap option over here with like the whole system coming in around £50, which gives you plenty of pipework to cut up and make something!

Just want to get my diesel running sweet with a meaty sound thats not too harsh on longer journeys. With waste veg oil on tap I want to start using this van alot to get through my rather large stock!

[R.O.R-2.0]

I'm leaving the forum if another one of you guys starts another muffler thread! jk!  The turbo is the muffler!

No one is stopping you. The turbo is not the muffler, the muffler is the muffler. If you actually clock any mileage in a vehicle you appreciate how its nice to be able to talk to your passenger sat next to you or even think.


I did consider putting a flexi in, but also realised that mk1 version of my engine install, the system was actually mounted to the engine as you find it in a vanagon. So I may go down this route. I think maybe the engine rattles more than it used to, its been in there for 4 years and covered a good few thousand miles before it broke the first time, then this time it went in 500 odd miles.

I am not overly happy with my current setup so I am getting some mufflers as found on 90s Land Rover/Range rovers 4x4's, which have a main muffler and a small one near the end of the system. Theres lots of systems for them, but I am selecting parts from the 2.5TD as I figured with rangerovers being a premium 4x4 means they are quiet, without hurting performance too much, this coupled with the fact you'll end up with an exhaust system that breaths for 2.5 litres with only a 1.6l breathing through it. Equally being the UK landrover parts are generally a cheap option over here with like the whole system coming in around £50, which gives you plenty of pipework to cut up and make something!

Just want to get my diesel running sweet with a meaty sound thats not too harsh on longer journeys. With waste veg oil on tap I want to start using this van alot to get through my rather large stock!

ive got a 12" exhaust system.. a 90* elbow, and 10" of exhaust tubing..

i can talk to my passenger perfectly cruising down the highway..

the only thing that bugs me, is i have a hole in the floor of my trunk, and a bad trunk seal, soo you smell it..

[745 turbogreasel]

The 3" on my Volvo 2.5TD droned like a mofo at 67 MPH without a muffler.
Cummins has open DP, you can't talk on the freeway.  Sounds like it's ready to eat babies at idle though.

The van is a muffling challenge, because long pipes are inherently  quieter.  An OEM muffler from pretty much any 2.5-3 liter econo car will do a  good job without too much restriction.

[R.O.R-2.0]

The 3" on my Volvo 2.5TD droned like a mofo at 67 MPH without a muffler.
Cummins has open DP, you can't talk on the freeway.  Sounds like it's ready to eat babies at idle though.

The van is a muffling challenge, because long pipes are inherently  quieter.  An OEM muffler from pretty much any 2.5-3 liter econo car will do a  good job without too much restriction.

my buddies cummins had just a downpipe, and a log truck stack welded to the end of that.. it was basically just a huge side-pipe.. it was LOUD. i could ALWAYS hear him on the highway, going up the hill a few miles from my house, that thing roared unlike anything ive ever heard.. it had a HX35 w/ the wastegate welded closed..

it also sounded like it ate babies for breakfast, when it was sitting there idling.. he never had anything bigger than a #10 (400hp) fuel plate in that thing either..

[745 turbogreasel]

I think I'd be a lot happier  with mine if it went past the back of the cab,  fumes come up the seat bolt hoes, and it's ass.
I'll get a temp something on there, and build a 4" system after I catch up  on  repair stuff.