[Vwdiesel] new SS dual exhaust for my Jetta TD
Area31 Research Facility
stephensrw at stn.net
Tue Jul 5 13:57:03 EDT 2005
I gave up trying to find some commercially available mufflers with low back
pressure that were within my budget so I ended up making a pair of 6"
diameter and 16" long stainless steel glasspacks (rock wool filling).
Thrush Turbos at $50 each were about as expensive as I could afford and
they are too restrictive. The Dynomax are twice the price of the cheap
Thrush so those were out. My own design is extremely low back pressure,
much lower than the Dynomax I'm sure and employs an absorber only along one
half of the cylinder rather than completely circumferential inside around a
central tube like in commercial glasspacks. Mine have no central tube. Now
the entire exhaust system is stainless from the toilet bowl flange to the
dress tips under the rear bumper. I just took it for a spin after hanging
the mufflers this morning and it is nice and quiet. At idle I get good
balance from both outputs and the entire system appears to develop enough
heat to at least bake dry in the summer during use. I am very pleased with
It took me more than four full shop days to fabricate this system. The
stainless cost me nothing, came from salvage from the landfil site stored
for several years awaiting a project. Hangers and clamps (not stainless)
cost about $12, and welding and grinding materials and energy probably
didn't cost more than about $100, so for a complete, over the axle dual
stainless exhaust I'm doing just fine..
I asked if someone might like to post my pics. No-one responded. I will
gladly send pics by private email to anyone who requests them. I haven't
got any yet though but should have in a couple of days.
BTW, addressing Bryan's last comment. In a turbo system I do not see how
any backpressure beyond minimally achievable due to necessary piping would
be desireable. It would only rob power from the turbocharger.
> ----- Original Message -----
> From: "82 Diesel Westy" <dieselwesty at yahoo.com>
> To: "Area31 Research Facility" <stephensrw at stn.net>
> Sent: Tuesday, July 05, 2005 11:54 AM
> Subject: Re: [Vwdiesel] new SS dual exhaust for my Jetta TD
> > Sounds like a wild job you did, any pictures Rob,
> > can't quite picture a dual exhaust system weld job in
> > my head.
> > Thanks, Bryan
> > Most of the vanagon guys with the AAZ 1.9TD motors
> > have only 1 muffler or none at all, the turbo does
> > most of the work. They use a turbo strait muffler as
> > well, work great and does provide some back pressure.
> > --- Area31 Research Facility <stephensrw at stn.net>
> > wrote:
> > > I am in the quest for better fuel economy and more
> > > power.
> > >
> > > Back pressure and exhaust system rust-out is now a
> > > problem in the past tense
> > > for my '91 turbo diesel Jetta. I just spent the
> > > past two days beating
> > > myself up fabricating a trick, cutom fit, over the
> > > rear axle, true dual
> > > 1-7/8" exhaust system. Both pipes begin at the
> > > bigger now than stock hole
> > > in the spring clamped stainless funnel flange at the
> > > engine. It is two
> > > independent, parallel 1-7/8" O.D. , 1/16" wall
> > > thickness stainless pipe runs
> > > all the way to the back where a corvair 2" x 2"
> > > turbocharger reverse flow
> > > muffler will go where the original muffler was on
> > > one run and the second
> > > turbo muffler will be mounted 90 degrees to the
> > > direction of the car and
> > > behind the spare tire well feeding a second exhaust
> > > pipe outlet on the other
> > > side of the rear where there was a dress cover
> > > hiding a pull point. All
> > > bends are weld on, constant cross section pieces.
> > > This exhaust system would
> > > have cost more than the car is worth if I had had a
> > > professional shop make
> > > it.
> > >
> > > No mufflers on it yet (auto parts stores are closed
> > > today)but because of the
> > > turbocharger it is quiet enough to drive. Shame I
> > > cannot get a half size
> > > turbocharger muffler. I don't need much quieting.
> > > With the turbo mufflers
> > > I expect I will have surely reduced back pressure on
> > > the turbocharger to
> > > just 20% of what it was stock. There was a
> > > resonator muffler in the middle
> > > of the exhaust pipe tunnel ahead of the muffler. It
> > > had a through cross
> > > section of less than 1-1/2". It is gonzo.
> > >
> > > This was a very horrible job and my poor body needs
> > > to heal. Burns, cuts
> > > and bruises. It would be soooo nice to own a hoist!
> > > I went stainless
> > > because I NEVER want to have to fabricate another
> > > custom dual exhaust system
> > > for this car ever!!!!!! Around here a normal steel
> > > exhaust system lasts
> > > maybe two years with all the salt they put on the
> > > roads.
> > >
> > > I should put this exhaust system in my Will. ;)
> > >
> > > Rob
> > >
> > > _______________________________________________
> > > Vwdiesel mailing list
> > > Vwdiesel at vwfans.com
> > > http://www.audifans.com/mailman/listinfo/vwdiesel
> > >
> > Bryan Belman, Pt Pleasant, NJ
> > 04 Jetta Wagon TDI PD, 100hp, 5sp
> > Rebuilding 82 Diesel Weekender from my old rusty 82 Westy 1.9NA
> > 90 Audi 200, 2.3L Turbo FWD
> > 70 Type 1 stock Beetle
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