Date:         Wed, 24 Sep 2008 07:21:45 -0700
Reply-To:     Don Hanson <dhanson@GORGE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Don Hanson <dhanson@GORGE.NET>
Subject:      Exhaust system help
Content-Type: text/plain; charset="Windows-1252"

Hey Neil,
  Glad to hear your van is operational..On my 84 with its' 50degree Golf
motor, I used 2 muffler hangers with  those rubber straps to support the end
of my system over where it exits at the passenger side, just ahead of the
bumper.  Muffler shops will have these part.  I can send you some pics
direct, if you need them, but I think I can explain well enough to give you
the idea.
  I took the main 'collector' pipe and welded a right angle bend just after
the flange that bolts onto the stock exhaust header casting. Turns the pipe
from "down" to back.   I ran the exhaust  back along side the motor and
turned it 90degs again at the rear of the block.  There, just after the turn
(the exhaust is now pointing at the passenger side)  I installed an oval
stainless Magnaflow muffler (about 21" long, with inlet and outlet offset to
the same side)  "ahead" of the muffler, I have one rubber hanger.  After the
muffler, another hanger. For the hanger after the muffler, we found a
convenient bolt in the frame rail, the other one I think we tack welded the
body end on somewhere.  This system has stood the test of about 50k hard
miles so far no problems and a very nice sound.  Kinda "quiet, industrial",
the sound.  The PO had a 12" round glass pack sticking straight back..Man,
was that one obnoxious, like many of the 'kid-cars" with the 4" outlet that
you see and hear...  The oval muffler (about 5" x 12" x 21") just fits into
the space between the rear of the motor and the body, at a slight tilt, and
gives better than stock ground clearance.  I chose the largest SS muffler
that would fit into that space.
  My only issue is my "temporary" cross engine brace, built by a tire shop
in Borrego Springs last winter, needs to be better engineered.  I found the
PO, who did my conversion, left that brace right off, and I almost "lost" my
whole motor without it when the long engine mount broke as a result of the
missing brace.  Or I need a stock diesel cross engine mount bar, which seem
to be out of production and a bit rare.
  I went to my FLMS (friendly local muffler shop) with my muffler in hand
(internet ordered) and we had the whole deal done in about 20mins with their
lift and all the right stuff right there.  $35 labor charge.

  Don Hanson