[Vwdiesel] new exhaust system for '84 Rabbit NA?

[Doyt W. Echelberger]

Much like Loren, I just had our local muffler shop rebuild our 1987 Jetta 
NA exhaust and it wasn't cheap.....mainly because I specified that it 
include a flex pipe between the down pipe and the muffler, nearer the front 
of the system. 
http://www.amazon.com/M2-Performance-Universal-Flex-Pipe-2-5/dp/B002FR44HQ

A flex pipe goes into every new exhaust system I put on a diesel, because 
over the years I have observed that they all eventually crack at some point 
without one....usually at a weld or a clamp. Diesels vibrate more than 
gassers, and the combination of a transverse engine at right angles to the 
mass of a longitudinal exhaust system introduces factors that result in the 
cracking.

I also asked for a resonator instead of a muffler on the final run, back 
near the rear axle...to keep the back pressure as low as possible. A 
resonator also reduces the weight of the system considerably, making it 
less vulnerable to vibrational cracking. A very heavy element like a 
muffler tends to shift the vibration to lighter elements like the pipes, 
and the welds end up cracking from the resulting focused 
vibrations.....thus the requirement for a flex pipe.

You should be able to get a decent system of aluminum-clad pipe for around 
$150-200, which would last for about 3 years even in the salt belt. Since 
you asked for shops that do this kind of work.....I had mine done by 
Rainbow Muffler, which has a string of shops in Northern Ohio. 
http://www.rainbowmuffler.net/home.htm

Doyt
 >>>>>>>>>>>>>>>>>>>>>>>>
At 03:09 AM 9/3/2010, Loren replied to David:

> >  Does anyone know of a vendor who builds replacement exhaust systems
> > for old NA Rabbits  ('84 2-door)?
> >
> > The exhaust manifold looks like it deserves a 2 1/2" pipe from the
> > manifold to the rear bumper.  David Ross
> >
>
>   I've just had the local muffler shop build ours.  With no turbo,
>2" is sufficient.  I've seen places that list factory (type anyway)
>parts including exhaust, don't remember where right now though.
>Usually cheaper and bigger to go custom.
>      Loren
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