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Engine Specific Info and Questions => IDI Engine => Topic started by: boxer246 on March 01, 2008, 06:52:28 pm
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I'm putting a 1.6TD in a caddy and will be building (or probably having someone build) a 2.5 exhaust front to back. My question is, what muffler(s) would you recommend for keeping good flow, while providing decent noise abatement? I'm not interested in the bellowing noisy sound like my buddy's Chevy Duramax has (he has a 5 inch from the turbo back)....To be honest the quieter the better. But I want it to flow good too. Should I use a "pre" muffler like they did originally on the diesels then a normal muffler in the rear?
Also, where would a flex tubing section be better served....in the downpipe going down or after it makes the 90 degree turn towards the rear?
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well i can answer this! i'm running a resonator and thats it! the turbo cuts down noise alot!
a 2.5 pipe all the way back will do? wont be loud much!
or if your concerned about having a muffler on ? use a magna flo or something simulare?
my caddy will have 2 side pipes with resonators just for a little back pressure! once i have time to finish it!
thanks Duane
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i dont even use a muffler,its pretty quiet
id put the flex after the bend ,,like "stock"
even a glasspack would tone it down if you need
2.5 inch pipe is fine
i get my own bends at summit,and weld my o wn systems
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Yeah I was going to get a few bends from Summit to weld up the downpipe and put a flex coupler in, but then just have a shop do the rest. Summit aslo has some generic "turbo" mufflers for a good price, they look decent, I thought maybe one of those would work OK.
So I probably wont bother with the glasspack or pre-muffler, just do a turbo muffler at the rear.
THanks for the thoughts guys.
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On my Caddy, I ran 2.25 to the biggest Magnaflow I could fit under it, then out to a nice stainless Magnaflow tip. 2.5 is a bit big for the chassis, IMHO.
The flex on mine is here;
(http://img.photobucket.com/albums/v648/stewardc/Truck/100_3275.jpg)
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Nice downpipe!! Looks sweet. Did you have it Jet-Hot coated or something or is that just hi-temp paint? How does it sound? Why do you say 2.5 is a bit big for the chassis? Too hard to make the bends or what?
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Nice downpipe!! Looks sweet. Did you have it Jet-Hot coated or something or is that just hi-temp paint? How does it sound? Why do you say 2.5 is a bit big for the chassis? Too hard to make the bends or what?
935racer is/was making these. he switched to 3" but not sure if he's making either anymore... they are costly to produce and as it seems, people complain about the 'high' price for this kind of quality :roll:
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Nice downpipe!! Looks sweet. Did you have it Jet-Hot coated or something or is that just hi-temp paint? How does it sound? Why do you say 2.5 is a bit big for the chassis? Too hard to make the bends or what?
This is Ceramichromed and it is sweeeeet. I tried the 2.5" but the chassis was so tight that we went with 2.25" instead. It makes for a very neat system and works very nice indeed.
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I am running a 3" straight-through system now. I had been @ 2.5" but it didn't look ridiculous enough as a side pipe. The 3" has less turbo whistle at idle :cry: but more at full-throttle :) . The 2.5" was louder and raspier at higher rpm.
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HOW COULD PEOPLE COMPLAIN ABOUT THE PRICE OF THAT QUALITY?
THOSE ARE DEFONATLY SOMETHING TO HAVE...
everytime i see that downpipe I get depressed to think my poor engines egt
this is the key to a modded vw so im told.
keep making dope parts PP
props,
-base
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I made a 2.5" flange to 3" downpipe for my 78 Scirocco. Purchased the flange and SS mandrel bent pipe. I'll confirm what the guys at PP said when I called to see if they had downpipe for a MK1. 3" on a Mk1 is a biotch! A 16V Scirocco shift arm will give you a little more room tho. I put the flex under the car right behind the steering rack after the 90, more room for it there. Worked ok for my ABA-16V turbo. I reused the 2.5" side exit pipe from the ABA-16V-T but haven't got the 1.6TD running yet, so can't say about noise level. Still some more wiring to do. The chassis harness was shot. :x
2.5" pipe and no mufflers sounds good on a 98 TDi tho
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straight pipes 4 life!
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good flowing pipes are a must when it comes to performance, on this we all agree, if you want performance with less roll and rumble while lifting the throttle (my wife does not enjoy that, as do some of us) may i suggest looking into Dr Gas Spintech mufflers. I have used them on many vehicles, and really enjoy the quiet while cruising...but lean into the throttle and a smile always shows up.
I imagine there are some that are always listening to the sounds your car makes. ( i can't help it, it's in the blood i think).
Your motor will make a very distinct sound with this muffler and i enjoy mine, with every note!!
The price is as good as the sound....(spintechmuffler.com)
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I just used an OEM style muffler. As others have mentioned, it will not be very loud even with no muffler but I wanted OEM quiet and I got it just with this single muffler. I installed the flex coupling in the bottom portion but I'm still not sure whether that was the correct choice or not.
Pictures of my exhaust system are here (it is on a van):
http://motorheads.net/vw/turbobus/page4.html
-David
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I take it that flex fit thing eliminated the doughnut type thing? This might be something to think about considering I can't get mine to seal....
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Made a few and selling them on ebay uk.
(http://img239.imageshack.us/img239/4337/pipe005fi2.th.jpg)
(http://img249.imageshack.us/img249/1516/pipe2002kk2.th.jpg)
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link?
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Hmm... i plan to run a straight pipe as well/// where do i start that from?? right after the turbo or after the "C" clamps?? and i wana do a 3inches setup... will that be a problem on 1.6TD mkII?? like not enough space or not enough back pressure???
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on diesel the straight pipe starts at the turbo outlet. Problems in fitting a 3" pipe is the size. Quote from the shop that did my 2.5" on the Mk3 TDi " 14 years doin exhaust and I aint never put no 2.5" pipe on a VW..." :lol:
back pressure is the DEVIL!! :wink:
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So u mean i can do a 3" straight pipe?? and what do u mena by "back pressure is a devil"????
U mean its good??
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some folks on here have run 3" from the turbo all the back, so yes you can do that if you can make it fit.
I watched the movie "Waterboy" the ther day, "It's the DEVIL!!" was stuck in my brain. Big pipe= lower back pressure, turbo's usually don't like back pressure after the turbo.
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make one man. . . $60 in bends, $18 4-bolt flange, $20 flex pipe, 6-18 beers and like 3 hours. Plus you get to say you made it! I did 3" turbo back, side exit before the rear.
(http://i28.photobucket.com/albums/c225/gilligan5000/downpipedone.jpg)
Good luck, and have fun
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Thanx man!!!
I live in pakistan... so i cant get the flange here... i reckon i'll have to get one made...
so a 3" pipe is an easy fix.. aye?? like there is sufficient room in an mkII TD?
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Sweet!
I am getting some mandrel bent tubing in today from UPS hopefully, and I already have the flange, so i'm gonna get the mig welder out and go to town. Hopefully I can make something decent. I gotta get a flex coupler though. Right now I just want to get the downpipe on so I can drive the car. Right now I just have hot exhaust coming out the turbo!
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I take it that flex fit thing eliminated the doughnut type thing? This might be something to think about considering I can't get mine to seal....
What is this doughnut type thing of which you speak? I don't have anything like that.
-David
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I was at the exhaust faricator yesterday.. the turbo back flange cannot take the 3 inch pipe as the hole on the flange is about 2.25 inches... if i do get it welded.. i wont be able to tighten the 4 bolt on studs...
i really wana go for the 3 inch setup.. so i was thinking of either geting it tappered from the turboback end or going for the 2.5inch setup.
Guyss.... how can i go for the 3 inch setup.
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Taper it to 3" as soon as you have room.
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Where can a person source the flange that bolts to the turbo?
I plan to make my own downpipe for my 1.6td, as the cast down pipe has a few holes. I thought about making\cutting my own flange, but it feels like too much work.
HJ1
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i ran 2.5'' from cat back and my muffler actually fell off and i didnt put anouther one back on because it wasnt any diff in sound not loud at all.. i just put on a brullen muffler on as it almost time for an e-test here so i need to pass but i put the muffler on and no change!!! same
i had 2'' (stock) i did install 2.5'' as i heard was better for flow, motor was just overhauled so dont wanna push it to much yet but soon i will see if the exhaust did anything......hoping it will as it cost me a bit of coin!
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Where can a person source the flange that bolts to the turbo?
I plan to make my own downpipe for my 1.6td, as the cast down pipe has a few holes. I thought about making\cutting my own flange, but it feels like too much work.
HJ1
from ATPturbo.com part number ATP-FLS-032 worked for me. 2.5" pipe at turbo outlet, opening up to 3" as soon as I could.
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Thanks! :)
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hmm!!
cheers!
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anyone have pictures of the PP exhaust manifold by chance?
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Sorry, no pic, but it's like a small header.
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thanks! but thats the downpipe
do you have any of the exhaust manifold? i know i saw a pic of it at some point in time on here i just cant find it
and might anyone know how much they are?
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anyone have the pp header pics? or their price? i just want to get an idea before i call to order... haha i want to know if i have enough in the bank
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(http://i94.photobucket.com/albums/l83/935racer/3rdmanifold.jpg)
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oh my gosh! haha
thank you soooooooooooo much
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Can also be seen here
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake4.jpg)
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake3.jpg)
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake5.jpg)
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jaw on the floor... that manifold is so style
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Where can a person source the flange that bolts to the turbo?
HJ1
homemadeturbo.com
Look around for weir technologies (spelling?)
Some guy in canada that has a cnc plasma cutter makes stuff dirt cheap.
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make one man. . . $60 in bends, $18 4-bolt flange, $20 flex pipe, 6-18 beers and like 3 hours. Plus you get to say you made it! I did 3" turbo back, side exit before the rear.
Good luck, and have fun
Nice work on the custom downpipe.
Can you post a shot of the side exit exhaust?
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I'm impressed! I'm working on running the same original intake and the tapered exhaust manifold. I am working out the details to turn the exhaust manifold upsidedown and positioning the turbo above and toward the front of the engine. This should allow me to simplify the plumbing to and from the intercooler. All of this will go into a 1966 Volvo which has a lot of room to do some nice engine work. Again, beautiful work! The intake and the exhaust deserve one another.
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Just finished the exhaust on my caddy 1.6td project....I used a mandrel bent 2.25" 90 for the down pipe and went up from there ending up with a factory style resonator and 2.75" dump tube right in front of the left rear tire ....love that sound!!!!
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what kind of a head is that in those pictures?
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what kind of a head is that in those pictures?
TDI
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make one man. . . $60 in bends, $18 4-bolt flange, $20 flex pipe, 6-18 beers and like 3 hours. Plus you get to say you made it! I did 3" turbo back, side exit before the rear.
(http://i28.photobucket.com/albums/c225/gilligan5000/downpipedone.jpg)
Good luck, and have fun
I am ready to build my own downpipe and exhaust and was wonderring what bends you used for the downpipe. It looks like you cut up a couple "U" bends to make this setup. i just want to make sure i buy the right stuff and only have to order from someone once.
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I did my whole exhaust with this kit...full 3" turbo back....
http://store.racing-solutions.org/3on4rasuexbu.html
this place is cheap and easy to deal with... 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe2.jpg)
I made all my flanges...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe9.jpg)
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I did my whole exhaust with this kit...full 3" turbo back....
did you use the rest of the bends for the rest of the exhaust system and just buy straight pipe from your local auto parts store. if so im guessing there are extra bends left after building the dp to do the rest of the exhaust. Just want to make sure i understood you correctly
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I wish they had a 304 S.S. kit...
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did you use the rest of the bends for the rest of the exhaust system and just buy straight pipe from your local auto parts store. if so im guessing there are extra bends left after building the dp to do the rest of the exhaust. Just want to make sure i understood you correctly
Yeah, what he asked. :P
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I'm trying to decide on either 2.5" or 3". If I'm only going to run 15PSI max, what do you guys think?
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Anybody know where to get stainless steel flex pipes for a good price?
Oh, and it wouldn't hurt if they were in Europe :)
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I'm trying to decide on either 2.5" or 3". If I'm only going to run 15PSI max, what do you guys think?
Wont matter, the larger exhaust would still be beneficial.
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I did my whole exhaust with this kit...full 3" turbo back....
did you use the rest of the bends for the rest of the exhaust system and just buy straight pipe from your local auto parts store. if so im guessing there are extra bends left after building the dp to do the rest of the exhaust. Just want to make sure i understood you correctly
yes I had some 3" straight from another project....I only need about 3' of straight.
I had 1 180* bend left over....I probably could have used it but I got sick of fitting pipes.. :lol:
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Anybody know where to get stainless steel flex pipes for a good price?
Oh, and it wouldn't hurt if they were in Europe :)
I got mine from the same place I got my piping kit...
http://store.racing-solutions.org/flco.html
they are just as cheap as summit racing on flex couplers....but they are not in Europe....
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Thanks mate, those are OK prices, but in my case the shipping costs would kill the deal...
I guess I'll just have to keep browsing through the eBay :)
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Thanks mate, those are OK prices, but in my case the shipping costs would kill the deal...
I guess I'll just have to keep browsing through the eBay :)
Is England to far? I know a few people on the vwcaddy.com have built theirs with pre-manufactored bits. Don't have the links off hand but will later.
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Thanks mate, those are OK prices, but in my case the shipping costs would kill the deal...
I guess I'll just have to keep browsing through the eBay :)
Is England to far? I know a few people on the vwcaddy.com have built theirs with pre-manufactored bits. Don't have the links off hand but will later.
Europe would be just fine. I have one quote from an eBay seller, and it's quite good price, but the shipping cost is a bit steep.
I need two flex pipes anyway, one for the turbine outlet and one for the separate downpipe for the waste gate..
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flex section for the wastegate!? talk about overdoing it.
How does a 2.5 run right out of the passengers side fender sound? Smoke the ricer in more ways than one.
Thats the plan for me. SS tubings and bends are easily bought from truck supply houses.
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flex section for the wastegate!? talk about overdoing it.
How does a 2.5 run right out of the passengers side fender sound? Smoke the ricer in more ways than one.
Thats the plan for me. SS tubings and bends are easily bought from truck supply houses.
Well, I'm trying to avoid too much sound 8) Silent death is more fun for me!
About the second flex pipe, hey, that's absolutely necessery! Every time you see a twin-downpipe design, the W/G downpipe always needs to have a flex pipe of some sort before it's connected back onto the primary downpipe.
You need it because when the primary downpipe sees somewhat constant temperatures during driving, the secondary downpipe becomes hot very rapidly every time the waste gate opens, and after that quickly cools down again. You can see what would happen were it not for the second flex pipe! :)
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I guess I dont mind mine being loud....
the Tial 38mm wastegate is gonna be vented to atmosphere.
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I'm putting a 1.6 turbo diesel in my 1966 Volvo wagon along with an Isuzu truck intercooler. This looks like a great setup. I have the same manifold that you started with and I was wondering what it was like to weld the components together. I had just about decided to go with a fully fabricated intake as well as exhaust. I was worried about the different grades of aluminum between the cast manifold and the tubing. I also remember cast aluminum being porous and holding oil residue that can mess up a nice weld. What was the source of your aluminum tubing? I was wondering also why you went with such a large diameter on the exhaust tubing. I was thinking of using something about 1.5" in diameter for my exhaust manifold. What size and style of turbo are you using? The photos are great. Do you have more to post?
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I got my system from Techtonics and it's great. it's 2.25 in. and I wouldn't go any bigger. just my 2 cents.
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Ive read this tread and read about a few members having difficulty getting tube/ bends etc.
I collect truck exhaust systems 2/2.25/2.5/3 inch sections or lengths and cut em up for my 'system'...
I wear out my face a bit at the local 'truck centre', but i wouldnt dream of paying for bends etc... it increases the 'selection' of bends at hand etc...
naturally I'll proberly be told this is all wrong for some reason... but I cant see the difference....