Date:         Tue, 15 Nov 2011 10:06:53 -0700
Reply-To:     Tom Buese <tombuese@COMCAST.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tom Buese <tombuese@COMCAST.NET>
Subject:      Re: Exhaust Design Contemplations...
In-Reply-To:  <BAY152-ds12F0D9E7577EABBBE94270A0C10@phx.gbl>
Content-Type: text/plain; charset=us-ascii

I guess I have underestimated the rusting conditions in the Rust Belt?
But living in Utah where we do salt the roads in the winter, I am on only my second 1.9 exhaust system in my 84, except for the cat which is original after 28 years & 147k miles!   2nd exhaust parts were 1st, muffler, then connector pipe, then all the other pipes, all Dansk, IIRC. The exhaust however has taken at least yearly maintenance for leaks caused by excessive vibration?  I even have a TK HD muffler strap welded to the muffler, but gaskets, copper nuts, pin hole leaks have been a recurring issue.
I think I have 1-2 missing support struts which might exacerbate the vibration, but after you mentioned your 3 new exhausts in 10 years, I wonder if you are missing more supports, have even more vibration that normal to account for the worn out exhaust system?

YMMV,

Mr. BZ-been Midasized



> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> Evan Mac Donald
> Sent: Monday, November 14, 2011 7:51 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Exhaust Design Contemplations...
> 
> Ok everybody - its time we tried to replace the tire thread with a new one -
> 
> 
> I own an '85 with a 1.9 WBX. I put stock exhaust systems on 3 times in 10
> years, then put on an S & S header. It also lasted about three years, but
> with less driving. ( Michigan winters, see.) The first, and main point of
> failure on the
> 1.9 system was the wretched two-into-one join at the collector. Each of the
> three systems that I have had fail went there first. By a noticeable
> stretch. 
> These were not cheepie repro, but real Dansk items.
> 
> When I look at the design of the 2.1 system, I see that this weak spot has
> been replaced with a very different design, using a casting in that
> particular weak spot. (As an aside, I also noticed the design of the 2.1 1 -
> 3 and 2 - 4 headers flanges at the collector end was also changed, to keep
> you from any partial updates to your exhaust. Grrrrr....)
> 
> And I am also ignoring cat converters and mufflers. I put my own mufflers
> on, thank you very much, and they aren't VW standard.
> 
> My simplistic question, attempting to ignore as many extraneous variables as
> possible is:
> 
> Which exhaust design is better? 1.9 Or 2.1? Pros and cons are what I mean. 
> The stainless issue is also not to be considered here, before you even
> mention it.
> 
> Better breathing?
> 
> Longer lasting?
> 
> Stronger?
>  Evan Mac Donald 
> 
> 
> "...in the absence of facts, myth rushes in, the kudzu of history."
> -Stacy Schiff