1600 CT exhaust, mine has a hole!

[ed_the_robot]

As the title suggests

So our van, Doris has just completed a 500 mile round trip across to the welsh coast and back!

She drove brilliantly.. But that's for another thread. Keeping it technical, we noticed a bit of popping on the overrun, and by the end of the trip she was sounding a little like a tuned dragster

There is a hole on the drivers side exhaust, before the silencer, about the size of a pound coin.

At some point in her life, the heat exchangers have been removed, so what I have is a very simple looking exhaust system. There has been a weld repair, MOT style (and not good) and this is what has failed.

So, what options do I have for this engine type? Ideally I'd be interested in an off the shelf j pipe, does a system without heat exchangers exist?

I guess I could get a replacement section made up? If anyone knows a good place in around nottingham that could do it, that could be the best option for me.

The last option would be some kind of stainless system, replacing the whole lot.. As its all bound to rust eventually! But I haven't seen a single system for the CT engine

Any help appreciated!

[kevtherev]

Where have you looked for the ezhaust?

[ed_the_robot]

I've taken a look on vw heritage, just kampers, brickwerks and a few other suppliers I found by googling.

Vw heritage and just kampers stock the part I need, but that's with the heat exchanger combined into the pipe.

Everything associated with the heating has been removed on our bus (I guess someone did it as a low cost solution to rusted heat exchangers) so effectively all I need is a simple bit of pipe with the correct fittings popped on the end.

It looks like the heat exchanger has actually been ground off of the pipe, and the damage welded back up to seal the system. Or someone has chopped the exchanger out and welded in a section of pipe. It's a poor weld near the silencer end, just above the engine mount bar that's failed, leaving a big hole behind.

[ed_the_robot]

Would these fit?

http://www.justkampers.com/071755-j-tub ... 2-bay.html

In place of this

http://www.justkampers.com/070-256-106- ... -1983.html

I know the CT shares its underpinnings with the earlier engines, if someone could confirm this would work, that'd be ace

[b-f-c]

If you look at the CT exchangers, you'll see a weld around the exit pipe. That 'S' section is the difference between the two, so the bug tubes wont fit.

Post a pic of your exchangers so we can see how bad they are, you might be able to use beetle exchanger parts to repair yours.

[ed_the_robot]

Ok chaps.. Here are the pictures!

Offending hole



Here is the heat exchange less system





Possibly the original pipes with the heat exchanger gubbins ground off?

The weld at the hole is like chicken poop.

The studs at the cylinder head are very rusty, so I'm a little worried about attempting the removal myself.

Any thoughts gladly appreciated!

[b-f-c]

They look custom made, nothing like the original, cracked at the weld from the J tube to the extension




More info here, http://www.tunacan.net/t4/tech/ct-cz.shtml" onclick="window.open(this.href);return false;

Probably the cheapest option is to have it welded?

[CovKid]

Or weld a bendy section of pipe onto the bug one?

[ed_the_robot]

Cheers guys, so as long as the system doesn't leak and is welded properly, it can be made out of several welded sections? I can't remember MOT rules exactly, sounds about right though aye

The section is probably salvageable then, if the rusted/poorly welded area is cut out and replaced I don't know if I'd gain much starting with the beetle parts.

Doesn't surprise me that nobody makes an aftermarket exhaust system for the 1600, though lots of people would get to admire it as they flew past me on the motorway

[dan]

Hi.
Do you still have this bus and this exhaust set up?
I'm looking for this exact thing.
Cheers,
Dan

[ed_the_robot]

Haha wow, old thread!

Yes, still got her. Currently I'm rebuilding the engine as it expired, due to a dropped valve.

The exhaust is pretty much scrap, I've got a full original exhaust with heat exchangers to bolt on.

What are you after?

[dan]

Wow, I was never really expecting a reply to this but gave it a shot anyway!!

What i'm looking for is to use the J-Tubes as a template to get identical ones made for my van as the old exhaust is knackered and I have an Eberspacher so don't need any of the heat exchangers. I don't suppose you still have the old J-Tubes do you

Thanks, Dan.