Author Topic: aaz downpipe modifacation swap? (Read 4905 times)

Clintwalker85 · « **on:** February 02, 2009, 12:22:12 am »

is there anything you can do to modify or swap a stock aaz downpipe so you don't have to spend an arm and a leg getting one made?

vanbcguy · « **Reply #1 on:** February 02, 2009, 12:43:26 pm »

Swap an AAZ downpipe on to something else? Make a new downpipe for an AAZ? Not sure what you're asking about...

People are spending big bucks to get custom downpipes made, usually larger ones than stock rather than just getting a stock equivalent downpipe...

myke_w · « **Reply #2 on:** February 02, 2009, 01:21:02 pm »

tttuning makes em for mk2's for under 300 bucks.. might be worth looking into. The quality is good and 300 bucks isnt a whole lot for a nice stainless downpipe. The other alternative is to have one custom welded, but I'd guess it would be close to the same money.

GEE-BEE · « **Reply #3 on:** February 02, 2009, 01:34:34 pm »

Contact Josh at Tectonics Tuning

He has a Jetta AAZ Stock downpipe from my AAZ swap

I sent it to him for a mockup for my Caddy AAZ

I found a Passenger Performance that I will probly send him also for a mockup, It will fit all MK1 with a 1.6 or 1.9 Motor's

I hope this helps others here..

Gee-Bee

Smokey Eddy · « **Reply #4 on:** February 02, 2009, 03:26:55 pm »

if you know anyone with a mig they're quite easy to make (i learned)

IT will rust through eventually but at production cost being almost nothing, no harm in wipping one up again.

I used old HVAC coolant oil piping that was otherwise doing to be melted down.

With just a chop saw and a mig welder with a stainless steel spool i went from this

to this in only ....
4 cuts and 4 welds i think?

High temp paint will help too! This one is 2.5 inch ID. Need a bracket though to hold it to the block as it is fairly heavy compared to the stock one. The old one works well just get out that mig again.
it should be treated for some gross sh!t so it shouldn't disintergrate from some hot exhaust TOOOO quickly. It's no tigged shiny piece of gold but for most of us on the forum (i think?) we don't have show cars and something of this calibre is acceptable. . . . ?questionmark?

edit: 3 cuts - 3 welds used the old cast flange

1slowvw · « **Reply #5 on:** February 02, 2009, 06:37:54 pm »

Acceptable indeed, mine was made from 2.5 exhaust tubing welded with a Mig, works great. Nothing fancy but it flows way better then stock.

1SlowVW

Rabbit TD · « **Reply #6 on:** February 02, 2009, 07:19:31 pm »

Quote from: "1slowvw"

Acceptable indeed, mine was made from 2.5 exhaust tubing welded with a Mig, works great. Nothing fancy but it flows way better then stock.

1SlowVW

What dia. actualy is the stock one to begin with, I'm going to be making one up for a 1.6 T/D soon similar to what you did also probably 2.5 and am wondering how much bigger 2.5 is over stock. I just tried my new mig welder out this weekend for the first time on some different metal thicknesses and I sure don't call myself a welder but I couldn't believe how nice it is on exhaust tubing, I can't wait to actualy make something with it

Smokey Eddy · « **Reply #7 on:** February 02, 2009, 08:31:53 pm »

i cut the 1.6td DP apart to find out and it's smallest spot was about 1.5 inch ID to be modest. It's those tight bends that really make it suck.

Clintwalker85 · « **Reply #8 on:** February 02, 2009, 09:35:13 pm »

can anyone make me a custon 2.5 inch downpipe PLEASE let me know

Clintwalker85 · « **Reply #9 on:** February 02, 2009, 09:36:25 pm »

i am skilled with a welder i have 4 of my own but i don't trust my cuts and measureing lol thats why i would like someone else to do it up if possible

Rabbit TD · « **Reply #10 on:** February 02, 2009, 10:23:24 pm »

Quote from: "Clintwalker85"

i am skilled with a welder i have 4 of my own but i don't trust my cuts and measureing lol thats why i would like someone else to do it up if possible

I've been thinking when I attempt this about using a tailpipe expander to open one of the connection mating points for each bend as the cuts wouldn't need to be perfect and even alow you to move things around a little to get the best fit before welding. That should help a little to get things lined up and even be stronger shouldn't it :roll: I never tried anything like this before but what do you think :?:

Clintwalker85 · « **Reply #11 on:** February 02, 2009, 10:41:27 pm »

thats actually a great idea i have 2 tail pipe expanders too lol

Smokey Eddy · « **Reply #12 on:** February 03, 2009, 12:37:52 am »

when i did mine it was not hard in the least what so ever.
I used a CHOP SAW to cut the pipe. I didn't even use a grinder to get the cuts "perfect" i used a grinder to remove burs and to make a valley for the weld to fill.

You can adjust the cuts a LOT just with welding.

I found by having a 22.5 degree bend with a 90 degree bend i could possition the whole thing how ever i wanted to fit. just make sure the length isn't too much (i think its 16 inches?) throw it into 5th and mock it up like that.

It was so easy i mocked up my down pipe without the car even being there and it fits perfectly.

Any imperfections can get corrected with a flex pipe (which you need anyways)

Clintwalker85 · « **Reply #13 on:** February 03, 2009, 12:59:08 am »

want to do the dirty work 4 me?? lol

Smokey Eddy · « **Reply #14 on:** February 03, 2009, 01:01:17 am »

What is your engine/model?
What are you willing to spend? Remember shipping would be brutal from here to you... like ... just unreasonable. It will be an awkward shape and heavy....
As much as i need money i really suggest you just find some scrap 2.5ID pipe/bends and try making your own...