Date: Sun, 9 Mar 2008 09:14:44 -0700
Reply-To: Robert Keezer <warmerwagen@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Robert Keezer <warmerwagen@YAHOO.COM>
Subject: Re: I4 conversion exhaust - some comments
In-Reply-To: <c35.2c33e51e.3504df80@aol.com>
Content-Type: text/plain; charset=iso-8859-1
Frank's muffler design is what I origallly tried
to do with my I-4.
But I found a 6-bolt flange Tiico downpipe to
which I had the bellows welded .
This goes into a cat and and then a Vanagon 2.1
muffler, exactly like the Tiico set-up but with
the added flexibility of the bellows to prevent
cracking .
Solid mount Tiico flanges crack.
If possible to get the Tiico downpipes this can
save you a lot of trouble. It's pretty much a
bolt-in with fabbing up the left bracket the main
delay, and welding the bellows on.
Robert
1982 Westfalia
--- Frank Grunthaner <FrankGRUN@AOL.COM> wrote:
> In a message dated 3/8/08 8:05:41 PM,
> sfcompost@YAHOO.COM writes:
>
>
> > 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.
> >
> Sam and other interested parties,
>
> When I developed the Audi 3A turbo, I used a
> run to the front-then turn
> around and go back approach. The Audi 80/90
> manifolds are definitely the best for
> the I4 gas system. Alistair had to do some
> clearance nibbling on the 4 to 2
> manifold and I didn't have to on my version.
> For the Audi turbo, I used the Audi
> 80/90 CA (for California) 4 to 1 version, since
> it matched the turbo inlet
> well. For the exhaust, I used the Saab turbo
> flex downpipe (stainless net wrapped
> bellows) then went through the air-cooled
> heater port and up the drivers side
> to a large bore muffler I studied the VW Golf
> mufflers with the 90 degree
> offset of inlet and outlet. I liked the idea of
> coupling two of them together
> to build the 180 degree reversal to run the
> pipe back out to the rear. In the
> end, I couldn't fit them in place so I went to
> a large oval muffler (Dynamax I
> think) that had inlet and outlet on the same
> side. So 2.5 inch pipe in and out
> with the outlet running back to the rear. I
> used a long and round resonator
> at the exit, passenger side running along the
> side of the sound-deadening pan.
>
> The muffler and exhaust pipe was supported by
> universal heavy duty truck
> muffler supports. My space limits were given by
> the propane tank on one side and
> the auxiliary diesel/fuel tank on the other. I
> also encountered some floor
> heating and added a heat shield. My target was
> quiet and this system has certainly
> delivered. I had engineered out vibration
> previously and no new vibration was
> introduced by this system. No breakage either,
> but the expansion/contraction
> lever arm (also vibrational and torsional
> stress) was resolved over a distance
> 5 to 8 times longer than the stock system.
>
> For the TDi, I left this system in place. When
> I get back to California, I
> try to get some pictures, if there is interest.
>
>
> For the I4 gas, the Audi 80/90 and Alistairs
> approach should be fine. I went
> from the Audi 2 port flange to a 2 to 1
> collector then to a bellows and out.
> All hanging from the original muffler mounts.
> Details on Bell's website and
> these comments from faulty memory while
> feasting on Nürmberger Bratwurst and
> Augustinerbrau.
>
> Frank Grunthaner
>
>
>
> **************
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