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Engine Specific Info and Questions => IDI Engine => Topic started by: Jettagli16v on February 15, 2009, 07:56:02 pm

Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 15, 2009, 07:56:02 pm: I made an exhaust for my 85 Jetta TD.
Everything is Stainless, even the innerlock liner on my flex coupling.
3" from the turbo all the way down the tunnel, and then 2.5" over the axle and to a dump.

Here go the pics:

This is what we removed... Anyone need a perfect stock exhaust?
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120199.jpg)

This is my welding compared to my friend Chuck's.... I should have stuck to tach welds....
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130212.jpg)

This is the adapter from ATP to a 3" V-band.
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120197.jpg)

The downpipe:
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130231.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130232.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120200.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120207.jpg)

The straight piece down the tunnel, and the over-axle.
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130240.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130243.jpg)

We had to piece together the tailpipe out of leftovers, but it is pretty close to what I had in mind at the beginning.
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130242.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130209.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120205.jpg)
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2120204.jpg)

Testing its ability to paint black stripes on the ground:
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130246.jpg)

My buddies shop (all the tig welding):
(http://i556.photobucket.com/albums/ss9/jettagli16v/P2130213.jpg)
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 15, 2009, 08:00:21 pm: Also, I will have to work on a video... the noise is a breathtaking symphony.
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 15, 2009, 08:25:23 pm: with the tip pointed to the ground, the sound seems to go in all directions, including forward to me....
not sure if I prefer that, or not.
Title: I made an exhaust... What do you think? (many pics)
Post by: camboscams on February 15, 2009, 08:59:09 pm: I Like!!! Needs a 3 inch store bought turndown to seal that perfect exhaust!!!....IMO
Title: I made an exhaust... What do you think? (many pics)
Post by: AudiVWguy on February 15, 2009, 10:04:00 pm: Lose the tip, every time the exhaust flow has to make a turn it creates a restriction, reducing your exhaust gas flow. The air going by the car creates a scavenging effect and helps pull the exhaust out of the pipe.
Just my 2 cents. 8)
-JB
Title: I made an exhaust... What do you think? (many pics)
Post by: 8v-of-fury on February 15, 2009, 10:57:33 pm: shexzi shexzi!

but I do agree about not agreeing on the last bit of the project..:lol:

Were you already done the case when you hit the axle? lol what happened to that tip it looks out of place.. maybe tuck it up under the car some more, and angle the tip (or loose it) so it doesnt make a 90 degree..

i'm sorry the rest is BEA-utiful, but dayyyumm.. wth? lol good job none-the-less! :P
Title: I made an exhaust... What do you think? (many pics)
Post by: Heavy D on February 16, 2009, 01:23:14 am: lol wanna make me one but only from the turbo too the down pipe?$$
Title: I made an exhaust... What do you think? (many pics)
Post by: Smokey Eddy on February 16, 2009, 03:42:40 am: seeing the stock exhaust on the shop floor AWAY from your car is a good feeling eh :P
Title: I made an exhaust... What do you think? (many pics)
Post by: spencebm on February 16, 2009, 06:31:26 am: link to exhaust flange adapter from atp?
Title: I made an exhaust... What do you think? (many pics)
Post by: zukgod1 on February 16, 2009, 06:47:13 am: Quote from: "spencebm"
link to exhaust flange adapter from atp?

/\ x 2 /\

Looks really good I think. I be however your going to end up moving the end. After a while that breathtaking symphony will get annoying.
Out the back and regardless of what everyone else has said I would still leave the turndown on it.
You have free'd up the exhaust enough it wont hurt a thing and by having that turndown on there your going to help keep the soot off the car.

Good job man looks beautiful!! :D
Title: I made an exhaust... What do you think? (many pics)
Post by: 53 willys on February 16, 2009, 08:08:19 am: I too would like the link to that adapter!!

your SS exhaust set-up looks great!!
you just need to cut the tip some more...turndowns are supposed to look more like this...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe5.jpg)

nice job...cut the tip and you will be golden!!!
Title: I made an exhaust... What do you think? (many pics)
Post by: rallydiesel on February 16, 2009, 09:34:44 am: Your buddy made the downpipe? That's pretty sweet. You could probably sell a few here.
Title: I made an exhaust... What do you think? (many pics)
Post by: zukgod1 on February 16, 2009, 10:05:13 am: Quote from: "rallydiesel"
Your buddy made the downpipe? That's pretty sweet. You could probably sell a few here.

I would bet you are correct!
Title: I made an exhaust... What do you think? (many pics)
Post by: Heavy D on February 16, 2009, 12:47:45 pm: I want this Ill buy one!!
Title: I made an exhaust... What do you think? (many pics)
Post by: kaneb on February 16, 2009, 12:49:26 pm: Very nice work.

I need 3" exhaust for my bunny.
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 16, 2009, 03:57:41 pm: Anyone inquiring about buying these products,
please contact: [email protected]
(Tell Chuck you saw my exhaust... He has only done one on a TD)
We did not make a Jig for it, for easy replication,
but I would totally go back up there for a day to help out the GTD folks..

ATP Flanges:
Flange (T31 outlet to 3" V-band in mild steel)
ATP-FLS-029 (this is a sweet flange in mild to do a 3" DP)

I used:
T31 outlet to 2.5" X 3" transition, and 3" V-band in Stainless!
All together, this adapter will run $95. (and only 1.75" long!)
If you want this, call them and reference quote #286266.

If you want the proper flange to weld 2.5" to in SS,
part# ATP-FLS-084
Transition # ATP-FLS-003

*** I thought this flange was perfect, but it does hit the wastegate bolts a bit.. had to shave a lil off the bottom..

Turndown:
Hey, Give me a break!
It was assembled with leftovers and scrap!
(Thats why I have a V-Band before the tip piece: I can remove it in 5 minutes, and adjust and change as needed!)

I am thinking switch the 90 turndown for a straight 45, and keep the same angle.
I really like the side exit.

53Willys:
"you just need to cut the tip some more...turndowns are supposed to look more like this...
And all diesels are supposed to look like big bumper GLi 16vs, but we are not all as lucky as you!

Thanks for the compliments,
-Brad
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 25, 2009, 03:58:54 pm: Does it make sense that I got about 3-4 MPG out of this mod alone?
It is only one tank,
but I got 39.76 and (I can only assume) I am driving it harder just to hear the beautiful noises!

Previous was between 35-39.8 MPG,
with a consistent average of 36-37.
I drive pretty hard all the time...

-Brad
Title: I made an exhaust... What do you think? (many pics)
Post by: jtanguay on February 25, 2009, 04:18:40 pm: Quote from: "Jettagli16v"
Does it make sense that I got about 3-4 MPG out of this mod alone?
It is only one tank,
but I got 39.76 and (I can only assume) I am driving it harder just to hear the beautiful noises!

Previous was between 35-39.8 MPG,
with a consistent average of 36-37.
I drive pretty hard all the time...

-Brad

yep... increasing the efficiency of the motor will help increase mpg. if you drive it like an old granny it probably won't do much though. :lol:
Title: I made an exhaust... What do you think? (many pics)
Post by: foxracer1 on February 25, 2009, 07:32:24 pm: Ha i pull a small trailer for my dirtbike and pulled a Rabbit truck on a dolly once got 34 with a tired engine. I drive so i can hear the pipe too. Its a bad habit i can't break.
Title: I made an exhaust... What do you think? (many pics)
Post by: myke_w on February 26, 2009, 06:20:38 am: Quote from: "rallydiesel"
Your buddy made the downpipe? That's pretty sweet. You could probably sell a few here.

That's for DAMN sure :)
Title: I made an exhaust... What do you think? (many pics)
Post by: myke_w on February 26, 2009, 07:04:50 am: Also - I could use a perfect stock exhaust :)

Not sure how you'd get it here, but I am in need of one.
Title: I made an exhaust... What do you think? (many pics)
Post by: Rabbit on Roids on February 27, 2009, 02:22:10 pm: lol @ all of us that cant keep our right foot off the floor. i swear all of us that like these diesels are all the same. who else finds themselves getting out of there car and popping the hood, even when it doesnt need it. and about you guys getting good mileage.. my car has seen 20 mpg, but its also seen almost 60 mpg too. the way it sits now, i bet i could get closer to 70 if i wanted. everything that is easy to take off, has been. no hood, trunk, doors, bumpers and most of the interior is gone.
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on February 28, 2009, 02:59:19 pm: [quote="Rabbit on Roids"who else finds themselves getting out of there car and popping the hood, even when it doesnt need it. [/quote]

Mine always needs a quick check to ensure all major components are still there!

Myke_W:
Send me a PM, Ill give you the components you need, cheap,
or if you want the whole thing, let me know... I cannot overcome shipping, but you dont really need to pay me much for it... I never know when I may need a favor!

-Brad
Title: I made an exhaust... What do you think? (many pics)
Post by: subsonic on March 01, 2009, 10:51:34 am: Is there a v-band before the flex coupling as well as after it?

If your bud can make up a jig and knock a few of these out for a decent price, you may be able to sell a fair amount of them as a pre-paid group buy dealio. Save time and cash for all involved.
It sure looks like there is the makings of a tubular manifold sitting on the floor in one of the pictures. Niiice. What is that for?

Jim
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on March 01, 2009, 12:36:11 pm: HAHA, I carefully took pics to see who was REALLY paying attention!
That is a T04 tubular SS exhaust manifolt for 16v.

Group buy would be a GREAT idea, that would limit my personal drives up to Jacksonville!

No V-band before the flex...
I have one directly off the turbo, and one at the bottom of the DP, so the whole DP can be easily removed.

Thanks!
-Brad
Title: ? DP
Post by: GEE-BEE on March 01, 2009, 12:43:22 pm: Iam in for one if you build them....

Gee-Bee
Title: I made an exhaust... What do you think? (many pics)
Post by: subsonic on March 01, 2009, 12:58:24 pm: Have you run into any heat issues with the pipe so close to your shifter linkage? I know that has always been the problem with fitment on our rides. I am going to be running a CTN tranny so I don't think I will have that concern though. What did you use for your flex joint? I know there are lots of variations for that piece.
Title: pipe
Post by: citigolf on March 01, 2009, 02:34:19 pm: i want that downpipe!!!! :D
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on March 01, 2009, 06:26:41 pm: If you want it, email Chuck, hell make it.

Subsonic:
I havent run into any issues as of yet (3 weeks or so with it)
If I do, I was considering the "missing linkz" kit from www.4crawler.net... He replaces your plastic end rods with heim joints, and the rubber bushings with "UHMW" trflon which is supposed to have amazing heat tolerance.

Also, I may or may not wrap the downpipe anyway. I always liked the look and it is supposed to be a big improvement as far as heat insulation.
I was shocked to see a header wrap kit for $80 at the local autozone... Have not yet gone to the internet to look.

(And I would do it right now, except I am trying to spend $200 I dont need to for a set of Schroth "quick-fit" harnesses... look em up if you dont know. Ill let you know if I win them!)

-Brad
Title: I made an exhaust... What do you think? (many pics)
Post by: Rabbit TD on March 01, 2009, 07:22:34 pm: Quote from: "libbybapa"
I haven't owned any ball-bearing turbos and certainly haven't taken any apart, but have had a curiosity for a little while. I have wondered if one could find ball-bearings that have the correct I.D. and machine a journal bearing turbo housing to accept the proper O.D. and so convert a journal bearing turbo to a ball-bearing turbo. Would it be more involved than that?
Andrew

I think it would b interesting too. If I was thinking about trying it I think I would first try to get some pictures of the internals of both with as much detail as possible to see what he differences are to begin with. It would be nice to use the actual bearing that Garrett uses if possible as it already is known to withstand the heat which would probably be the biggest issue and also the seal the ball bearing one uses if these parts are even available to us. It would be interesting though to see how it would work.
Title: I made an exhaust... What do you think? (many pics)
Post by: Jettagli16v on March 02, 2009, 11:13:51 am: Got the harnesses!

Look up "Schroth Quick-Fit for VW/Audi/Seat/Skoda"

Really nice piece!
Title: AMEN
Post by: T.D.Tuner on March 02, 2009, 06:31:30 pm: If ya'll could keep acouple spare down pipes around the shop Im posotive you could start a small business. Id be in.