Club 80-90 Forums

There are a few topics running on this subject so I thought I would put it all into one post that people can find in the future when they search for exhausts. I assume forum users do search first before asking?

These are for the most common watercooled 1.9 and 2.1 petrol engines and are not in any particular order

First of all you need to find out what exhaust system you have. Is it the early type or the late type? If your van was registered in 1985 don't go off your registration year as your van may have been built earlier than 1985.

The early exhaust was from 1980-1985 and the silencer is unsupported
The late exhaust was from 1985-1992 and the silencer is larger and supported by two saddles

The attached images at the bottom of this post show what the two types look like as you may have a post 1985 van where the tightwad previous owner fitted an pre-85 exhaust system.

Standard mild steel Exhaust

Standard mild steel Early and late exhaust systems available from

1) Justkampers - Exhaust system bundle packs available
2) German Swedish and French Car Parts (GSF)

Late DG/DJ Stainless Exhaust Systems

1) Brickwerks sell an exact stainless steel copy of the original late exhaust system.

2) Jp Exhausts sell as well as fit their own late exhaust version.



3) Turbo Thomas sell their version of the late exhaust system

4) It is also an option to fit the vwspeedshop early style exhaust system (see below for web details)

Early DG/DF Stainless Exhaust System solutions

1) VW Speedshop sell a stainless system that will fit both early and late vans.

2) Brickwerks are currently developing replica early stainless steel exhaust systems in consultation with their supplier.
UPDATE 11/07/2011: Brickwerks are currently testing prototype early system pipes http://brickwerks.wordpress.com/2011/07 ... e-exhaust/" onclick="window.open(this.href);return false;

When they become available it will most likely be posted on the Brickwerks facebook page

3) Consult your local Longlife Exhaust Centre to see if they will build you a custom exhaust

See an example here https://club8090.co.uk/forum/viewtopic.p ... 0#p7594110" onclick="window.open(this.href);return false;





4) Some members have reported that Turbothomas supply early stainless exhaust systems.

5) Fit the late style stainless exhaust to your early van.
The silencer needs supporting on the late system so the parts required are 2nd hand Engine Mount (025-199-221A) and longer M10x85 bolts, Silencer Saddles and straps . (Stainless from Brickwerks or 2nd hand VW originals)

If I have missed anything (most likely) let me know

Custom Alternative Options

https://club8090.co.uk/wiki/Exhausts_Custom" onclick="window.open(this.href);return false;

Well Done mate , youve got the Job

Great post Cruz

Well done for taking the time to collate all the info.

Dont forget CovKid's great home brew option https://club8090.co.uk/wiki/Exhausts_Custom" onclick="window.open(this.href);return false;.

kevtherev wrote:Great post Cruz

Cheers Kev

It's all about making the learning curve easier for others

Would it be wise to add this to the wiki or make the topic sticky?

Doing it Cruz. Just got the text in for now, will add the hyperlinks. Waiting for Harrymann to return so we can reorganise the exhaust main categories but I've made a start on it

Might be worth mentioning that its an idea to keep an eye on VW Aircooled suppliers, who sometimes have T25 parts. My new silencer came from Machine7 during one of their half price sales and is good quality - weighs a ton, anyway. Good quality mild steel parts may last longer than you think if a full-on stainless system is beyond your budget. The old mild steel silencer (unknown make) on my DG had lasted 9 years!

Also, there may be some doubt over the quality of the cast knuckles currently available. Brickwerks even said theirs were made of poorer metal than they would have liked. I bought one anyway, and found that the casting needs considerable fettling on sealing faces and bolt hoes to get them square and ensure everything bolts up correctly. The actual metal though, seemed to be very good - nice close-grained iron with no blow holes. Once tweaked and fitted, it sealed first time and has given no problems at all.

Oldjets

Thanks folks, thats more or less got the exhaust section into some order now and thanks Oldjets for your thoughts - added also. If anyone else has created their own exhaust system or fitted a box from some other vehicle, would be pleased to hear from you and what you did to make it fit. This would expand the 'custom' section a little then. The main thing is to offer as many choices as possible to fit all budgets. Not everyone has £500 to throw at a complete replacement stainless (I know I haven't!) and sometimes need a solution to get them out of trouble, so trying to provide as many options as possible beyond 'off the shelf' replacements, including any repair options for MOTs etc.

https://club8090.co.uk/wiki/Main_Page#Exhausts" onclick="window.open(this.href);return false;

Shiney JP Exhaust

tut tut rusty engine carrier

looks great cruz, proper job that is

kevtherev wrote:tut tut rusty engine carrier

I know. Looks like I'll be on my back again with a steel wire brush soon

Why did they change the design from early to late?

That's definitely one for the anoraks

eatcustard wrote:Why did they change the design from early to late?

Because how the old system was set up there was no easy place to put a catalytic converter in and to get all the gasses from all the cylinders to pass through it while they were still hot.