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Sat Apr 27, 2013 3:40 pm

ivwshane wrote: No, do they have to be replaced right now? They aren't welded to the existing CAT (I plan on getting an exhaust hardware kit from germansupply).
This cat isn't welded to the elbow?

Quote: AutohausAZ has the F-pipe you will need for the bolt on factory style cat.

http://www.autohausaz.com/search/product.aspx?sid=...tor%20Pipe

They actually have all parts from cat to tail pipe but they don't sell the CARB stamped cat model legal in California.
Chris - You mean elbow and not F-pipe. Dansk makes them and it is extremely hard to find a NOS genuine VW one. A good used one is Ok too. EMICO has a CARB-II legal cat and they will sell it direct - at least they did for me. It has the CARB-II stamp and the ARB executive order number on it.

Sat Apr 27, 2013 3:44 pm

Steve, that has to be a modern O2 bung welded to his elbow. He's all set if the plug is able to be removed.

Sat Apr 27, 2013 3:48 pm

Sorry for the incorrect terms, I always thought that was the F-pipe. I guess the f-pipe is the crossover?

Sat Apr 27, 2013 3:48 pm

SGKent wrote: ivwshane wrote: No, do they have to be replaced right now? They aren't welded to the existing CAT (I plan on getting an exhaust hardware kit from germansupply).
This cat isn't welded to the elbow?

Quote: AutohausAZ has the F-pipe you will need for the bolt on factory style cat.

http://www.autohausaz.com/search/product.aspx?sid=...tor%20Pipe

They actually have all parts from cat to tail pipe but they don't sell the CARB stamped cat model legal in California.
Chris - You mean elbow and not F-pipe. Dansk makes them and it is extremely hard to find a NOS genuine VW one. A good used one is Ok too. EMICO has a CARB-II legal cat and they will sell it direct - at least they did for me. It has the CARB-II stamp and the ARB executive order number on it.

I have a replacement pipe coming (used, I think I posted the samba ad in my previous post). This is the pipe that is connected to the drivers side of the CAT. On the passanger side of the CAT it's just bolted to the muffler.

That should be all I need in terms of exhaust pipes, right?

Did I miss it somewhere or has anyone suggested what gaskets I should use and from where?

Sat Apr 27, 2013 4:02 pm

ivwshane - your system has been modified by a muffler shop. To go back to factory you will need the elbow, cat, muffler, and maybe tailpipe.

The factory style has doughnut joint like the bug tailpipes use (but bigger) between the cat and the muffler. Yours has a flange so something would need to be modified to accept the factory style cat.

I am betting that plug on the current system is correct for using a diagnostic wideband O2 sensor. See if you can remove the plug with some heat and penetrating oil. If it has threads that will fit the same sparkplug the engine uses you don't need to touch a thing on the exhaust.

Sat Apr 27, 2013 4:36 pm

Chris_914 wrote: ivwshane - your system has been modified by a muffler shop. To go back to factory you will need the elbow, cat, muffler, and maybe tailpipe.

The factory style has doughnut joint like the bug tailpipes use (but bigger) between the cat and the muffler. Yours has a flange so something would need to be modified to accept the factory style cat.

I am betting that plug on the current system is correct for using a diagnostic wideband O2 sensor. See if you can remove the plug with some heat and penetrating oil. If it has threads that will fit the same sparkplug the engine uses you don't need to touch a thing on the exhaust.

Ah crap! Damn you guys are good with your good eyes:p

My setup looked stock except for a welded exhause Y pipe but now I see that my muffler has a flange where it should just be a pipe to pipe connection:(
Damn it!

Ok so where is the best place to get a stock muffler? Are they all pretty much the same or is there something I should look out for?

I see busdepot carries two muffler that look exactly the same but the part numbers are slightly different:
071251053CAN and 071251053C but there is about a $40 difference in price.
http://www.busdepot.com/071251053can
http://www.busdepot.com/071251053c

Sat Apr 27, 2013 6:29 pm

ivwshane wrote: Chris_914 wrote: ivwshane - your system has been modified by a muffler shop. To go back to factory you will need the elbow, cat, muffler, and maybe tailpipe.

The factory style has doughnut joint like the bug tailpipes use (but bigger) between the cat and the muffler. Yours has a flange so something would need to be modified to accept the factory style cat.

I am betting that plug on the current system is correct for using a diagnostic wideband O2 sensor. See if you can remove the plug with some heat and penetrating oil. If it has threads that will fit the same sparkplug the engine uses you don't need to touch a thing on the exhaust.

Ah crap! Damn you guys are good with your good eyes:p

My setup looked stock except for a welded exhause Y pipe but now I see that my muffler has a flange where it should just be a pipe to pipe connection:(
Damn it!

Ok so where is the best place to get a stock muffler? Are they all pretty much the same or is there something I should look out for?

I see busdepot carries two muffler that look exactly the same but the part numbers are slightly different:
071251053CAN and 071251053C but there is about a $40 difference in price.
http://www.busdepot.com/071251053can
http://www.busdepot.com/071251053c

do you have a Federal or a California bus? Look on the driver door for a silver sticker. Does it say Catalyst?

Sat Apr 27, 2013 6:53 pm

It does say "CATALYST".

Sat Apr 27, 2013 7:32 pm

God damn man, I feel for ya on this one. It's a good way to learn your engine when you have to go through it like this and have basically no choice. I learned my engine after my 68 beetle with a supposed 'rebuilt' engine dropped a valve on the highway leaving me stranded. Haven't looked back since. I am just super glad St. Louis doesn't do emissions on cars pre 96. I'm rooting for ya though.

Sat Apr 27, 2013 8:42 pm

ivwshane wrote: It does say "CATALYST".

well then get a used elbow WITH A GOOD EGR MOUNT from someone like Chris at busted bus, Ken at Busco, Avery's aircooled in Washington. You will need a muffler, one of the German ones is best but they will cost about $150 delivered and will have to come from classifieds. Get a new tailpipe - they are cheap. They rust thru because of debris thrown against them from the passenger wheel. Also get the gaskets. You might want to look at your strap and see if it can be removed or if they welded that too. Just get a new strap if you can and don't forget the gaskets*. When you get ready to take it off and mount the new ones, come over and take a look at my bus or I can snap some photos for you.

*
Elbow to heat exchanger
Elbow to crossover pipe
EGR gasket
Elbow to CAT
Cat to Muffler donut
Muffler to tailpipe

Sat Apr 27, 2013 9:19 pm

Steve does he also need emco Cali CAT instead of there 48 states CAT? only asking as the OP lives in Cali.

Sat Apr 27, 2013 9:41 pm

SGKent wrote: ivwshane wrote: It does say "CATALYST".

well then get a used elbow WITH A GOOD EGR MOUNT from someone like Chris at busted bus, Ken at Busco, Avery's aircooled in Washington. You will need a muffler, one of the German ones is best but they will cost about $150 delivered and will have to come from classifieds. Get a new tailpipe - they are cheap. They rust thru because of debris thrown against them from the passenger wheel. Also get the gaskets. You might want to look at your strap and see if it can be removed or if they welded that too. Just get a new strap if you can and don't forget the gaskets*. When you get ready to take it off and mount the new ones, come over and take a look at my bus or I can snap some photos for you.

*
Elbow to heat exchanger
Elbow to crossover pipe
EGR gasket
Elbow to CAT
Cat to Muffler donut
Muffler to tailpipe

I'm trying to understand the parts I need but their names don't seem to be universal. I understand what the EGR gasket is as well as the elbow to the CAT (it's referred to as the exhaust Y pipe in the bentley), and I get what the muffler to tailpipe is.
However I don't know what you mean by elbow to heat exchanger. Using the Bentley as a reference, in chapter 5 page 15 are you referring to the front exhaust pipe?

I don't have any clue what you are referring to with the elbow to crossover pipe. I don't see any elbows connected to it other than the exhaust Y pipe.

And for the CAT to muffler donut can assume you are referring to the four piece clamp (upper/lower ring, middle gasket, gasket ring)?

I plan on getting the exhaust gasket kit from germansupply, this should have everything I need right? I don't see an EGR gasket in it though.
http://www.germansupply.com/home/customer/product.php?productid=18188

This is the correct EGR gasket right?
http://www.germansupply.com/home/customer/product.php?productid=17181&cat=&page=1

Sat Apr 27, 2013 9:43 pm

curtis4085 wrote: Steve does he also need emco Cali CAT instead of there 48 states CAT? only asking as the OP lives in Cali.

This is the CAT I'm getting:
http://www.emico-catalytic.com/appchart/product.php?prod=335057

This is the same CAT steve purchased and I'd have to assume that he wouldn't buy a non California compliant CAT.

Sat Apr 27, 2013 9:51 pm

And slightly off topic:

Anyone know of any coupon codes for germansupply:p

Sat Apr 27, 2013 10:07 pm

ivwshane wrote: And slightly off topic:

Anyone know of any coupon codes for germansupply:p

coupon code... :shock: :shock: you pay for what you get in the world of German VW parts.. Just bust out the cash and be very happy Germansupply is here as a resource for your buses needs.

Oh and be patient as Scott is a busy guy and some items will take awhile to show up. Mostly special order stuff.. hose kits,,etc..

Sat Apr 27, 2013 10:09 pm

I just noticed one potential major issue:|

My crossover pipe is welded to my muffler! Wtf am I supposed to do now?

Sun Apr 28, 2013 12:19 am

Start looking for crossover pipe. Chris at Bustedbus.com. Email him.

Sun Apr 28, 2013 3:08 am

I'm on bustedbus.com but I can't tell what part number I need because none of the setups look like mine.

24A is the closest but the ends of the pipe don't look right, they don't look like mine.

Sun Apr 28, 2013 7:26 am

Thiay help?

http://www.oldvolkshome.com/2exh7279.htm#251B

Sun Apr 28, 2013 8:42 am

you have the bottom two in the image above. In 1976 they ran air through a shroud around the crossover that looks like a bull's horns. In 1977 VW eliminated the bull's horns. I had a spare one that no one wanted, sorry I tossed it. They are available used. NOS one's I've only seen one advertised and I bought it about a year ago. Make 100% sure that the studs on it are intact and have good threads. Do not buy one with busted studs as heat hardened and rusted studs are a pain to drill out. You will work a long time unless you have access to machinists bits and a good drill press and table.

Here is a image from bus boys showing both the 1976 and 1977 variants of that piece. The red arrow points at the 1977 - 78 style. (Raul) VW76Westy http://www.thesamba.com/vw/forum/profile.php?mode=viewprofile&u=102766 may have some as I know he used to have an exhaust parts stash. He is in SO Cal.