Club 80-90 Forums

Morning folks

Two questions really. First of all, I have discovered some really big holes on my exhaust after replacing the front to back coolant pipes the other day. The right hand J-tube or heat exchanger (I think) is particularly badly corroded and the more I poke at it the more that comes away!! The hole is currently about 1" by 3" but I fear that would quite quickly increase if I wanted it too!! Bottom line is the exhaust is well shot and needs completely replaced - Plus Gas on standby . So here's the first question. Given that my van budget has been depleted after the cooling & fuel system overhaul, is it dangerous just to temporarily tape up the holes with aluminium tape, or some other product, whilst I save up for a new one? It was smoking a fair bit whilst I was bleeding it yesterday after replacing the front to back pipes and I am wondering how big/dangerous a problem this is? Obviously an MOT failure but thats not till Feb so will have it sorted out one way or another by then.

The second question is whether to replace the exhaust asap (particularly if it is dangerous in its current 'holey' condition), or wait a while till I can afford a stainless one. If so, can anyone recommend a stainless exhaust for the 'early' petrol DG's like mine?

Very much appreciated folks

anyone got any advice? cheers folks

The late system (as a complete unit) will fit yours. If the j-pipes are corroded than thats probably the best route. If it was just the backbox you can substitute with a different one (bike can) but theres not a big enough demand for the earlier one other than the few stock parts available and given the narrowing gap between a complete steel system and a stainless one, even those parts could dwindle eventually.

Roydini wrote:
The right hand J-tube or heat exchanger (I think) is particularly badly corroded and the more I poke at it the more that comes away...

If so, can anyone recommend a stainless exhaust for the 'early' petrol DG's like mine?

...not a 'heat exchanger' per the earlier air cooled engines, but a sleeve to source warmer air to go to air box then carb for cold starts. They all rot and they can be done without. Originally it would've had a length of flexi silver hose going from it up to plastic port on air filter box. You can get rid of the 'heat exchanger' and the hose. Simply pull off the rotten, rattly bits from the J tube (which hopefully will not have holes in it....if it does you will certainly HEAR it!)

Stainless full system for early DG engines available from VW Speedshop. Great system.

Sorry pics small though!