Exhaust options please...75-78 needed for 1977 late bay setup

[orwell84]

[Busdepot]

FWIW, the Pacesetter (which is the budget exhaust system I recommend, by far) is not Chinese made, it's made in the USA (and potentially Mexico as they have a second factory there). But its origins are Italian; it's a blatant knockoff of the ANSA VW0497 that went out of production about 15 years ago. http://www.busdepot.com/352000
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- Ron Salmon
The Bus Depot
www.busdepot.com

[69BahamaYellow]

Here's a picture of the inside of my EGR filter, after only 4 years.

Doesn't look terrible on the outside, but the inside is finished. All those rusty bits had made there way up the EGR pipe, through the EGR Valve, and into the intake manifold and clogged it up. No wonder the EGR idiot light comes on every 15,000 miles.

The problem is the plain steel construction of this and all the other exhaust components that are available today, aftermarket or OEM.

That Pacesetter muffler is a pretty simple design to manufacture, and it replaces a bunch of components with just 1 piece. I did not find it terribly difficult to make it fit. My only gripe is it's still too loud. If we could get them with some more baffling and stainless steel construction, I don't think most bus people would mind paying 3X the current price. Also, wrap a heat shield around it, since most folks are missing that piece too. (just in case the good folks from Busdepot are still following this thread)

[mikewire]

Interesting to see that EGR! I think I'm lucky I don't have to deal with that.

For those of you following along, parts showed up and I began to clean and mock up parts for high temp paint and assembly.

Here's what I'm working with:

Here's the exisiting extractor style exhaust:

After some wire wheel grinding and basic cleanup, I have this bolted up.

Items to address include...

getting a flange/clamp setup on the input side of the muffler. I think I'll run it down to a good exhaust shop and see what it will take to get a set of flanges welded up.

Copper lock nuts will be used. And a tailpipe gasket kit is on order. (THANKS BUS DEPOT!!)

I will prep for paint and go with a high temp (1000 deg F) BBQ paint in silver.

I'll keep posting up progress.
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-Mike

@countdowngarage
@bigskyeuro

1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC swap
1965 VW Beetle Deluxe Bahama Blue

[Abscate]

[Magion]

Should have gone with the CSP tail pipe like I did for two reasons.
1. looks pretty cool
2. The paint will not chip - does not apply if you have mud flaps.

Post some pics when done!
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1975 Westfalia in Brilliant Orange
1995 Westfalia in Caribbean Green

[mikewire]

[Bleyseng]

No, that one is too small as it's for the chrome tailpipes on a Bug/Ghia. You need to find the larger one that is NLA. I just installed one on Marc&Eliana's bus when they came thru on the way to Alaska
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles

[69BahamaYellow]

Finally got around to modifying my Pacesetter exhaust by cutting off the tailpipe and adding a small resonator and additional stinger tailpipe. I can confirm this mod is significantly quieter. Still not quiet as stock, but pretty close. This is well worth the effort if you value quiet exhaust.

[SGKent]

if that piece in the end is a full cone you are losing about 5% - 10% of your HP. I had to weld one in on a sports car once to legally quiet it and the drop is significant. If it is a partial cone then there would only be a small drop.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[69BahamaYellow]

[SGKent]

I was only concerned if it was a full cone which would create excessive back pressure which is what happened on the sports car to satisfy CHP. They used to sit by the side of the road on a grade and measure cars. I haven't seen that in years so there would be no need for it.

[69BahamaYellow]

Thanks for sharing that, SGKent. Hadn't seen one of those before, but I can see how restrictive those cones could be.


I don't have a tach on my bus, so I couldn't say for sure if I'm loosing power at the top end, due to my exhaust mod, but my gut feel is that my bus could match the performance you describe with your factory exhaust equipped bus.

The only real world test I can do is drive around a while and see if I can cover the same miles with the same amount of gas I was using before.


I would be curious to know what others have done to approach the same level of quiet (or better) that can be achieved with the factory exhaust, which I consider to be the Gold standard of balance between performance and quiet. There's a lot of science that goes into the proper engineering of an exhaust system

[SGKent]

[sblu]

Hi Folks, does anyone have any idea what supposed to attach here? Was underneath the bus removing the bumper and see that an attachment of some sort is missing!

[/img]
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1978 Westfalia Champagne Edition Project

[78wkndr]

Heat dumped tubes… An attempt by Volkswagen to better evacuate unused heat exchanger heat Farther down stream of the engine

Reminds me that I need to reinstall mine....

I am quite confident that these are only found used.

Maybe even 78 only?

https://www.thesamba.com/vw/forum/viewtopic.php?t=664428&highlight=heat+dump+tubes

Dan
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78 westfalia weekender F.I. 2.0
77 triple white beetle convertible

[SGKent]

I think 78 and 79 had them. Maybe air cooled vanagon too but I am not sure on that. Sitting in heavy traffic all the heat goes under the bus on 77 and earlier. That causes the fuel and trans to get hot. By moving the dump tubes behind the bus all that heat went away from the trans and fuel tank. The heat valves are always on - either dumping or to the cabin.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Jetfxr69]

[SGKent]

the booster doesn't come on but it is more than a trickle of air that comes out when the booster is off.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[sblu]

folks,
i checked the links in the other referenced thread and couldn't find a place to by these? any recommendations?
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1978 Westfalia Champagne Edition Project