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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Wed Dec 04, 2019 4:52 pm Post subject: Diesel SS 2½ exhaust, higher boost, more power! |
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New exhaust system for my AAZ! Seeing 3 lbs more boost, lower EGT, more power, higher revs and less smoke at the top end! Big improvement over the 2" pipes.
Above see the parts used (the shiny bits), except for the long 90Ί piece which was excess. My metal guy chopped them up to make the oddly shaped compound angled loop under the '83 carrier bar as shown below:
To the right the downpipe comes out of the turbo, I had him weld in an M18 SS bung for a future exhaust sensor. This section is connected to the turbo flange by V-Band clamp which makes rotating odd angles so much easier. The under-the-carrier section takes 3 pieces cut and welded together artistically. It goes into a 10" flex section:
You can see the engine carrier bar below behind the flex tube. It was important to me to vacate the space under the exhaust manifold as it gets pretty hot and the pipe through there interfered with the turbo drain tube. The 90Ί angle hangs off the frame box and is then V-Band clamped to a Moroso Spiral Flow muffler. Surprisingly effective for a small muffler. Apparently it works by shunting half the flow through a phase-shifting helix. The rest is pretty standard exhaust. This arrangement leaves a lot of space under the license plate/coolant reservoir area.
If you dont have at least 2½ exhaust pipes on your 1.9TD you are not operating at optimum. Determined empirically, because I ran the 2 pipes for 3 years. _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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dkoesyncro Samba Member
Joined: December 10, 2006 Posts: 982
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Posted: Wed Dec 04, 2019 6:16 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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I'm curious to the exhaust note the spiral makes, do you like it? What were you using before? |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Wed Dec 04, 2019 6:43 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Definitely sounds more like a clattering diesel but without excess exhaust noise. The old muffler was a Magnaflow glasspack straight-through type. The worst muffler for a diesel, but the exhaust shop that did it was ignorant. The spiral muffler sounds the same as the old one, but now my turbo whistles noticeably louder. Mostly it is smaller than the old one. Also the spiral is open-chambered, so it wont restrict. The glasspack tends to collect soot from the diesel at my elevation, and gets restrictive. Also the additional bends on this system absorb noise. _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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beach_creature Samba Member
Joined: April 11, 2014 Posts: 532
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Posted: Wed Dec 04, 2019 7:13 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Looks good.
Can you post some more photos of it when you get a chance? More of the bends around the carrier bars, the flex pipe, and exhaust mounts.
Very interested in this.
Thanks! _________________ 84 Westy
1.9TD AAZ
5spd manual with Locking Peloquin TBD |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12115 Location: Port Manteau
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Posted: Wed Dec 04, 2019 8:08 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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I'll confirm the straight-through glasspack condemnation. I really regret going with one on my TDI swap. I'm currently in the process of completely re-doing my intake and exhaust systems to further mitigate noise. I'm running 2.25" tubing. _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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outcaststudios Samba Member
Joined: February 09, 2015 Posts: 1732 Location: Maine
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Posted: Wed Dec 04, 2019 8:46 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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thread delivers. _________________ '88Doka JX td
'69 westy
(rip)couple bugs
(rip)three type III"s
(rip) '81 vanagon
a bunch of french stuff,and 9 motorcycles.
https://www.thesamba.com/vw/classifieds/detail.php?id=2573791 |
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dobryan Samba Member
Joined: March 24, 2006 Posts: 16501 Location: Brookeville, MD
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valvecovergasket Samba Member
Joined: October 10, 2018 Posts: 1491 Location: pnw
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Posted: Thu Dec 05, 2019 11:17 am Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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awesome stuff! i love vbands for custom exhaust work, and it makes service a lot easier as well
can you post some more pictures from further back when you get a chance? _________________ MegaSquirt resource - SpitfireEFI.com
gone, but not forgotten: '83 tdi westy - swap thread |
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vwwestyman Samba Member
Joined: April 24, 2004 Posts: 5688 Location: Manhattan, Kansas, USA
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Posted: Thu Dec 05, 2019 2:13 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Zeitgeist 13 wrote: |
I'll confirm the straight-through glasspack condemnation. I really regret going with one on my TDI swap. I'm currently in the process of completely re-doing my intake and exhaust systems to further mitigate noise. I'm running 2.25" tubing. |
Would love details on what you're doing and how it works! I cannot decide for sure if the noise I'm having is primarily intake or exhaust, but the drone is loud and annoying.
My setup is fairly similar to what the OP has done, I'm sure the pipes are 2.5 inches, mandrel bends, along with a smallish diesel cat and sprial flow muffler. _________________ Dave Cook
President, Wild Westerner Club
1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing |
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eleven Samba Member
Joined: July 10, 2019 Posts: 14 Location: North Carolina
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Posted: Fri Dec 06, 2019 6:22 am Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Excellent... This is on my list, along with a re-do of the intake to add an intercooler and proper filter box.
Nice work. |
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metropoj Samba Member
Joined: April 23, 2004 Posts: 1343
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Posted: Fri Dec 06, 2019 7:15 am Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Beauty stuff.
I need to build a similar exhaust for a 1.8T once it is mounted in the van.
I've read a few people piecing together from generic type off the shelf, Lego it together, and then get it welded up all proper like.
Where did you get your bits from ? _________________ John.
86 TiiCo powered Westy. |
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big swifty Samba Member
Joined: August 21, 2007 Posts: 246 Location: Formally in Republic of VT; now in Hollywood, FL
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Posted: Fri Dec 06, 2019 3:21 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Muffler details please. _________________ Evan
1987 Vanagon Syncro // Westfalia pop-top graft // Factory new ALH. 11mm IP. AFN 110 RC 2,3,4 // S7 turbo// Titan P502's
2013 Golf 4d TDI. No mods. Yet.
[1991 Jetta coupe TD. Giles Superpump. Custom tall 5 speed. SOLD |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Fri Dec 06, 2019 6:29 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Turbo out:
Downpipe:
Under carrier bar (small corrugated tube is diesel heater exhaust):
Exhaust pipe going back:
Flex section:
Muffler hangar and V-clamp:
Hangar off frame:
Spiral muffler (Moroso 94054) and tailpipe. Note clearance to get a socket in the 12point crankshaft bolt:
Tailpipe hangar:
Tubes I got from http://www.allpurposepipes.com and all other parts from Amazon. A hint on the tubes, they are very hard metal and your metal shop will need a saw with fine teeth, or abrasive cutter. _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Fri Jan 22, 2021 3:01 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Just an update on this, after running for a year I am very pleased with 2½ pipes. NO OIL BLOWING for a year! I did not realize my engine was suffering from unusually high internal pressure from the small exhaust. During my summer trip over the Rockies I was able to floor the pedal all the way up and not get excess EGTs like before. This system was something like $700 but well worth it. If you are building an AAZ, especially with a modified injection, you really need 2½ pipes. _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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erste Samba Member
Joined: March 29, 2013 Posts: 1110 Location: San Francisco
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Posted: Fri Jan 22, 2021 3:08 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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That exhaust looks really good. Nice work! |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12115 Location: Port Manteau
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Posted: Sat Jan 23, 2021 2:47 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Now I feel dumb for sticking with 2.25" exhaust.
I don't have too many oil leaks, except for persistent valve cover gasket seepage. I still don't quite understand the linkage between exhaust diameter and oil leaks. _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Sat Jan 23, 2021 5:52 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Thats what I had before this upgrade, 2Ό pipes. Back pressure, apparently my smaller pipes were not letting the turbo find a low enough pressure on the spill side. I dont know what your Waldo pump entails but if it is modified for perfiormance then a deeper breathing engine is a good idea. What diameter pipes did the stock ALH come with? _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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valvecovergasket Samba Member
Joined: October 10, 2018 Posts: 1491 Location: pnw
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Posted: Sat Jan 23, 2021 5:59 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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erste wrote: |
That exhaust looks really good. Nice work! |
x2 !
I think I mentioned it in the other thread but this was an inspiration for the exhaust we built for my swap and pjn_wyo's ahu syncro
We didn't do the vband break but otherwise more or less the same components.
_________________ MegaSquirt resource - SpitfireEFI.com
gone, but not forgotten: '83 tdi westy - swap thread |
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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6348 Location: Honolulu,Hawaii and France
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Posted: Sun Jan 24, 2021 12:11 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Gnarlodious wrote: |
Thats what I had before this upgrade, 2Ό pipes. Back pressure, apparently my smaller pipes were not letting the turbo find a low enough pressure on the spill side. I dont know what your Waldo pump entails but if it is modified for perfiormance then a deeper breathing engine is a good idea. What diameter pipes did the stock ALH come with? |
Could you explain the low pressure thing for the sill side?
I`m not sure I follow and I`m interested in this.
I`ve had 3 new CHRA pissing oil into the exhaust, quality parts .
1st one I rebuilt, I thought I messed up so I bought a whole new CHRA: pissing oil again, found some oil contamination. Flushed everything and installed a turbo oil line filter and a new 3rd CHRA. Pissing oil again.
I found a 20 euros 30 years old turbo ( junkyard find by a friend), had it shipped from France to Hawai`i.
Cleaned it, installed it, no oil pissing. I`m maaaad!!
Oil drain into the oil pan, like JX, no oil trap in the hose routing.... _________________ Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2319 Location: Adobe Jungle USA
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Posted: Sun Jan 24, 2021 12:42 pm Post subject: Re: Diesel SS 2½ exhaust, higher boost, more power! |
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Ouch, thats rotten. The spill side of the turbo MUST see as little back pressure as possible. If you are running a glasspack sort of muffler it makes a restriction. It's a common muffler shop mistake to put a glasspack on a diesel because the fiber collects soot which aggravates the back pressure. This sets off a cycle of poor combustion and even more soot
repeat.
I fought with oil leaks for 3 years, trying all sorts of solutions. Excessive exhaust pressure causes blowby and oil coming out various seals and openings. I was seeing prematurely black oil, high EGTs, black smoke and low boost pressure until I increased the exhaust flow.
The only downside to a bigger exhaust is the engine makes less heat, which I notice in the winter! _________________ Vanagon 83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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