I've been patching the exhaust on my old 94 for the last couple of years and at 450,000 km, I'm running out of metal to weld to. I think its time for a complete replacement so it can do another 450,000. Are there any good systems available that I can bolt in or should I get a muffler shop to build me something? Is there much advantage to up-sizing the exhaust on these?
Between the cat, resonator and muffler, there is a lot of s*** under this car. Does it really need it all? I have always been happy with the power in this car, lots more than my 1.6td and not much less than my TDI. I don't like a noisy exhaust as I drive a lot of hwy miles. Also would be nice to find a good source in BC if possible.
I think if your not after absolute power a 2 or 2.5 inch exhaust will be fine. Throw a glasspack or turbo muffler on it and it should be quiet enough for you.
I just did from the cat back on Jezebel - 2.5" all the way through with a dual-tip muffler in the back. Sounds good, not much louder than the stock system at all but sounds quite nice when you're deep in to the go pedal. My cat actually rotted out - I have a new 2.5" diesel cat in a box in my back seat but I don't have it on the car yet. I THINK I want to find a downpipe first, otherwise I'll be paying more for labour to have that cut in later on.
There's a Magnaflow cat-back that should work but it's 2.25" instead of 2.5"... I put one on my gasser Jetta, sounded FANTASTIC. The setup on Jezebel sounds pretty similar.
hottexhaust.com is a decent place to check out for us Canadians. Cheap stuff, search online for a coupon code as there's lots out there. That's where I got my magnaflow from.