Date:         Sun, 9 Mar 2008 11:28:25 -0700
Reply-To:     Phil Stanhope <surfmobile007@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Phil Stanhope <surfmobile007@YAHOO.COM>
Subject:      Re: I4 conversion exhaust
In-Reply-To:  <64C7D41C-B686-4951-9D12-06167B524482@shaw.ca>
Content-Type: text/plain; charset=iso-8859-1

"I think the secret really is using a flexible
coupling between the downpipe and the bend to the back
of the van, and using rubber hangers to suspend the
system along the back of the van."

Thats what i did and i like it. i used two 4" flex
bellows from EPI. i Put one in place of the stock 3"
Tiico flex bellows, and another 4" flex between the
muffler and the the cat. See pictures here:
http://autos.ph.groups.yahoo.com/group/tiico/photos/view/4ab1?b=2&m=f&o=0
Ed Mcklean came up with this design......i still go
thru diesel muffler bushings, but im going to ad a
rubber hanger at the cat to take some of the weight
load off the diesel bushings and that should solve it.
its been about 6months w/ No cracks in the exhaust
manifold.

Phil
84' Westy Tiico'ed in 02'


--- Alistair Bell <albell@SHAW.CA> wrote:

> let me chip in...
>
> I have found the stock diesel muffler hanger system
> to be fine. No
> cracking or such in 14 years. I have replaced the
> rubber isolation
> mounts twice. no flex coupling in actual pipe.
> I used the stock diesel exh manifold, pipe and
> muffler for quite a
> few years, then switched to the Audi 89/90 4 into 2
> manifold and an
> aftermarket muffler. But still used the stock diesel
> muffler hangers.
>
> Friend with similar conversion has had many cracked
> pipes with rubber
> hangers supporting muffler. I believe having the
> exhaust system
> coupled to the engine all the way is the best
> system.
>
> some info is on my website.
>
> Alistair
>
>
>
> On 8-Mar-08, at 7:58 PM, sam mccarthy wrote:
>
> Neil, with my I4 vanagon I had 2 different exhaust
> designs with
> radically different results.  The first set up I had
> built at a
> exhaust shop using an old Dasher dual outlet
> manifold, which angles
> toward the front of the van. I had the shop follow
> the example I had
> seen on a German engine conversion site which ran
> the exhaust forward
> through the aircooled heater tube hole, forward to a
> muffler hung
> under the center of the van, into a 180 degree bend
> back toward the
> rear and then out to the driver side ahead of the
> rear wheel. This
> required a simple layer of sheet metal as a
> heat-shield to keep the
> heat away from the floor, but worked very well and
> was almost too
> quiet.  No vibration problems whatsoever.  My only
> concern was that
> the cat was a bit too close to the transaxle. And, I
> liked having the
> exhaust coming out of the side of the van, as it
> told those
> discerning van-heads that this was no normal
> air-cooled van.
> When that exhaust began to fail, I had the same shop
> build another
> one. When I requested they build it further away
> from the transaxle,
> they suggested going to the stock location, and
> thought they could do
> it for similar costs.  It was a mistake.  Not only
> is this a much
> more costly design to construct, but vibration
> problems are a too
> often occurrence.  It took three redesigns, and a
> lot more cash
> before the vibrations and resulting cracking were
> solved.  And, with
> the short length of the stock design, it is often
> quite loud. I think
> the secret really is using a flexible coupling
> between the downpipe
> and the bend to the back of the van, and using
> rubber hangers to
> suspend the system along the back of the van.
>
> With my TDI install, I would rather go forward once
> again, but the
> 1990 body I'm using, there is no heater tube hole to
> route through.
> I'll have to go rearward.
> If you are looking for the right manifold to use,
> take a look at
> Frank Grunthaners' post in the archives, or within
> Vanagon.com as he
> has done extensive testing on the various
> possibilities and found
> that the Audi 80/90 dual outlet manifolds are the
> best.  The Dasher
> manifold I used worked well, but doesn't flow all
> that well.
> Good luck, I hope this helps,
> Sam M
>



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