Club 80-90 Forums

As I am sick of exhaust mounting rubbers going and also the pain of fitting them, I decided to go for a lighter sleeker design which also provides a straight through exhaust which will help to reduce engine temperatures. It is surprisingly quiet but with a slight throaty sound and no vibrations. In addition it will not foul on rocks like the standard silencer. Got a piece of pipe of a local exhaust place for five euros and used an exhaust clamp and made up a bracket to attach to the traditional mounting on the sump also incorporated a dead exhaust mount to provide some dampening. The pipe is only attached to the sump mount as it is so light, I have a flexi on my downpipe and seems to work fine. Again it is a first draft will attach a downpipe on the end to push gases out the back and will make up a heavier bracket, any recommendations would be appreciated, not sure if it would pass an mot but the noise levels are not excessive but we don't have to worry about that in Ireland campers are exempt!

Looks nice, with the low size there can't be too much weight on the bars to the sump, but over time surely the rattling of a diesel engine will cause some kind of fatigue failure at the weakest point? (guessing by metallurgy it's the sump ) maybe not if it's just a pipe, but that's not an option in the UK.

Here's my effort, I kept the rubber mounts as per normal design. The AAZ had a 2" pipe size from the turbo so went with that size for the whole thing, cut and re-welded the bits of exhaust I had from the donor car, plus some other bends here and there, figured it was worth keeping the flexi also.

flexi - anyone had any failures from mud n damp from the wheels causing some quick contraction? (stinking hot metal doesn't really like this too often) was thinking of putting some kind of shield on this, will prob fit mudguards also, might help a little bit?


I decided to go for a setup in two parts, just in case I wanted to take any part off for some reason (failure over time? or if engine needed to come out), and also because it would have been a right pain in the bum to wiggle the turbo end of it all through the gap between the chassis and the engine mount bar if it was all in one piece. plus it was easier to offer up, tack, re-check, etc. before fully welding. measure twice weld once

The two sections connect where one bit is flared with slits down the side, then a exh. clamp to hold it together. The silencer is same dimensions as the old 1.6D one I had (rotten) which was 24" long, 5" diameter - but with 2" straight through bore instead - made to measure Stainless! and I think it was around £50 from Mij exhaust, midlands (found em on evilbay). I ground off the silencer brackets from the old broken silencer (these are fairly hefty, so weren't rotten) and welded them onto the ends in the same orientation (take a photo first!) I could have invented some similar bars using stainless to keep it all the same but didn't have any material at the time.
The little tailpipe on it directs it down & out the back then, sounds fine n well happy with it.