Custom Exhaust for K-Jet Engine

[bmouthboyo]

Hi Everyone

Having finally removed my cracked manifold from my camper with a K-Jet 1.8 Gti Engine, I am now faced with the following problem.

The old manifold down pipe and back box are from what i think is a VW diesel engine??? and custom shaped to fit the T25 bay, however a lot of people have said that the current system, especially the manifold is strangling my engine, and i think could well have been the cause of the cracked manifold.

This is a picture of the old manifold that was fitted:



And this is the custom exhaust:



My question is that I would like to replace the single outlet manifold with a twin outlet Gti one as it would allow it to breath as it should, however that would involve having the rest of the exhaust custom made or adjusted. I am not after anything fancy just enough so the Gti lump can breath.

Firstly do you think its worth the hassle, as the previous owners obviously ran it fine on the restricted manifold and system.

If it is worth doing how much am i roughly looking at to have it fabricated? and how would i go about getting it measured up/ made,I have no welding skills or gear.

Thanks again for all your help

[bmouthboyo]

Any ideas? I am kinda in need of advice as I will have to purchase a another small manifold if not.

Thanks

[Fritz]

Simply look/search for a similar company in your area as I have liked to :::::::

http://www.ojzengineering.co.uk/" onclick="window.open(this.href);return false;

Regards


Fritz,,,,,,,,,,,,

Your location would help us to help you.

[bmouthboyo]

Ok thanks I have sent a few emails to them now

Just outa interest, could i bypass the manifold and just have a custom exhaust that buts up to the head , joins in a down pipe and attaches to say a Gti back box, with the end pipe re orientated so the back box can sit horizontally ?

Would I have issues with lack of back pressure? What about Cat converter, do i need one?

Thanks

[Simon Baxter]

That looks like a standard system from a 1.6D "CS" engine.

[bmouthboyo]

Really? It fitted perfectly to my K-Jet Mk2 Gti engine so I assumed it had been custom made.

[Simon Baxter]

Nope, thats just a standard 1.6D exhaust, the bore is tiny too!

[bmouthboyo]

If i fitted a Gti manifold and had a custom twin bore down pipe leading to a Gti rear silencer would i experience back pressure problems?

I assume the engine is designed for a longer exhaust and a mid silencer.

Would it matter what back box I get? Someone suggest a TD Transporter back box, even though my engine is petrol would this be suited?

Thanks

[BAYVELLE]

I have a whole k-jet lump sat on my workshop floor which was going in a mates van, but he has now moved to Sweden so has left me the lump to sell on.
Can sort you the manifold or the whole lump come to that, wont be a lot of money.

Came out of a mk2 golf gti

PM me if interested, im Near Street & Glastonbury if that helps.

[Echo Beach]

http://i30.photobucket.com/albums/c350/ ... age002.jpg" onclick="window.open(this.href);return false;

'up the skirt' shot of a friends recently converted k-jet install using the standard 6 bolt gti manifold and front pipe cut and shut to marry with a standard petrol backbox

[bmouthboyo]

wow thats exactly what I need, do you have any idea how much it cost him? And how I would go about having one made up?

I have spoken to a local exhaust garage and they said they can do one but my problem is I have no system on at moment so wont be able to take it there to measure up etc.

Cheers

[Technohippy]

That'd be my zorst then ... Hello...

Ingredients:

1 x Golf manifold
1 x Golf downpipe
1 x T25 Diesel back box and tailpipe
1 x heavy gauge bit of plate
1 x big old bit of stainless for a tailpipe (hell why not)
1 x bloke who's very handy with a grinder and a welder and ahs done this a few times

So... golf manifold, use the golf downpipe as a template to make a new flange ( fnarr fnarr ) from the plate then cannibalise the tubes from the downpipe making clever use of the curve already in it so that both pipes are the same length into the 2 into 1 cut the flange off the old tailpipe and weld that on the end of this assembly so that you can bolt the back box onto that ...


and weld the bit of stainless on so it looks nice thus



was all pretty cheap for parts as most of it was scrap bin stuff really.. it isn't very quiet but it does let the engine breathe well enough to scuttle the van along on the at a steady 80-90 (irony) without troubling the temperature gauge and returns me nearly 40mpg at a constant 55 (all the way to volksworld behind a 1200 beetle )

Labour cost.. one Nigel Storer at Precious Metal, Billericay, Essex ... difficult to say how much the zorst cost as he did it as part of the conversion but a day's labour I guess in the grand scheme of things

One more picture... the back box came off a TD that had blown up as was full of the gloopy contents of the engine so it needed a bit of a burn through before it went on.

Hope this helps