General Information > Upgrades (non engine related )

New exhaust system for my Mk2 Jetta

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scrounger:
My 86 Jetta TD is needing an exhaust. It has a stock system, two mufflers, one mid and one at the rear. The head pipe is loose and getting very thin walled. The exhaust isn't that loud guessing that the turbo is acting like a muffler. I wouldn't mind a straight through or minimally muffled system exiting from the side. I don't want a 500 dollar tuned system, just something that works. Does anyone have any specific ideas. Are those spring clips at the front much of a hassle?
Thanks
Dave

Dakotakid:
One option: 2 1/4 inch non-muffled all the way to the REAR. Reasonably quiet. All the stink out the back. Less vulnerable to bottom-outs. More civilized looking.

Yes, some guys see the clamps as a problem. All in how you go about dealing with them. I feel confident someone will show you a photo of a concocted spring spreader.

VWee:
Do you have some tips to prevent problems on the clamps?

srgtlord:
If you have access to a welder do yourself a favor and weld the exhaust together instead of using exhaust paste

scrounger:
Here we are about 4 years later, things sometimes work slow around home.

This summer put in  a new head pipe. The one I found was a non turbo head pipe.  It fit the TD Jetta okay, except for where it joins, it was straight wall instead of flared.  making it too small. I had some 1/8th steel that I shaped as a 2 part shim and everything is well clamped.  I used 2" muffler clamps reversed to remove the spring clamps. I think 1.75" clamps might work well but had the 2".

I hated to weld it as at least once in the past, I needed to take it off to replace the shifter ball.

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