JSW scheduled to be in the shop tomorrow for welding and fabrication work! Although we ran into a small snag that may put production out a little bit. The CNC mandrel bender shop busted their bender on our downpipes! They where trying to remove an extra weld that I would need to do so that it could be a true one piece pipe and busted some expensive parts on the bender. They where telling me it should be in this week or next so that they could finish up our order. Regardless, WE are moving forward with doing some installation tests and fitments again to get the test car ready for the final fitment. This includes a full 2.5"exhaust and tune to take advantage of the new hardware. I should be posting pics up on my facebook page this week to keep you guys happy .. but please be patient, I will be welding a lot and not eating much turkey this holiday to try and get these done for the end of the holiday season!
Sorry guys for taking so long! I just ate my first bit of turkey here Monday! Last week was a long week of welding, fabrication work, and administration stuff trying to get all the parts in to finish these! Sometimes things just really do not like going as planed!
But good news! One more item on the bench to mate up with the Downpipe... Full 2.5" mk5/6 jetta diesel exhaust
I also made up adapters for going to the stock exhaust for those not looking to run the downpipe and want more than what the other two companies are offering (My pipe removes the last rear box and muffler vs. just the muffler)
If interested in more pics check my facebook page out. I should have more info going up on that more often because I can take a quick shot with my phone.
I will keep everyone posted when the pipes gets in.. still waiting
Thanks for the I needed it after all the work this past week! To answer a few of your questions:
3" exhaust and downpipe are overkill for these smaller frame turbos, the most you will gain is louder exhaust noises and turbo spool issues from a lack of back pressure. If anyone is interested in going with a gt30V frame turbo or larger on these blocks and would like a custom setup let me know and I would be more than happy to build one. Right now though 90% of the people who own these cars are not at that point the stock and euro turbos have an outlet that is around 55mm in diameter. I have no idea where Banks got the idea that a 4.5" truck tip and exhaust is needed on these motors.. obviously you are paying more for the name and look than you are paying for true engineering work. (sorry my opinion, please take with a grain of sand).
The Aero muffler does two things: 1) It takes away some of the higher pitch exhaust noises and tones them down. 2) It allows user to meet local exhaust laws for places that say you need one regardless of if the car is quite or not. I will get some youtube videos up once things are done so you can hear it. It should be nice with the full downpipe and not too loud for most.
The initial downpipe price does not include tuning. I or Mark can offer a few options including just DPF delete, stage 1, or stage 2. Sadly the cost of the custom CNC fittings for the turbo, and all the sensors bungs drove up the price drastically. I really was hoping to get the prices lower, because I too know that is important, but I refuse to cut quality or corners to supply people with sub par products. If you also go out and look others are selling these at well over $1200 USD right now for just the pipe right now, I think coming in at a lower price really does show you I have all you guys in mind!
Mako- Can you do me a favor to help me and others out on here who may be in the same place? Can you take a photo of the under side of your car that clearly shows where the pipe ends and connects to your factory exhaust? I will also need you to measure things up. I may need to make an add in pipe or converter for other aftermarket exhausts. If It is just slightly short I can add it to the downpipes at little cost increase, otherwise I may need another part made up... It is hard to tell without have more info. Lets see what we can come up with.
Last edited by shortysclimbin; 11-30-2010 at 12:49 PM.
Is that a golf or jetta? The piece I was talking about that my exhausts is removing and that other companies do not is connected between your flapper valve and your new exhaust. The downpipes will be setup to connect to either a 2.5" pipe or someone can purchase an adapter to make it fit to the other side of the flapper valve. In your case you have a few options:
1) Get the downpipe and have the exhaust go from 2.5" down to 60mm through the flapper valve and then back up to 2.5" from about the rear seat back. This leaves you with ~4 feet of oem pipe
2) Get the downpipe and I can make up a custom piece for your car that should fix your problem. Although this will require cutting the aftermarket "exhaust" to remove the flange and get a true 2.5" exhaust system.
3) You could sell your exhaust and buy one of mine This would make fitment easier, but would not be the most cost effective solution for you.
If you decide to go with option two let me know I will need some measurements from you.
Ive seen the downpipe and tune pricing, and am very excited. I am interested in how much a package deal for the full exhaust, from downpipe all the way back, and the tune would total up to. That way i can see how much saving up i need to do. Also, is there any concern that the stock intake would be a restriction after these mods? thanks.
Still waiting on the bends. It seams link everyone is on holiday. As soon as they get in I will be working on welding up some and getting the test car back together. Then I am in hopes we should have some sound clips for you guys and pricing info.
As far as air modifications, I do think a few things could be done to improve things a bit. Although I do not know if these will give any proven gains from them alone. More or less they would be needed for stage 3 and 4
Sorry for being distant guys!
The initial goal of getting these out before Christmas is looking like it is going to be a no go sadly because everything that could go wrong has. I just received the pipes back from the benders and they have a mistake in the bending process that they need to fix. Regardless I am moving forward and doing more work to try and get a good test jig. I may need 3-4 members interested in a "demo version" of the downpipe to just make sure that they fit all models. I would prefer members with mechanical ability who may be able to give me feedback. These pipes will have a few more welds in them than the final versions and may require a little more work to install. If interested Talk to me on facebook (this goes direct to my phone so I know about it).
Also on the topic of the downpipe styles here is a picture of an early 2009 and a 2010 downpipe. VW has four versions of these and I have only been able to find two to test fit. I am confident that my jig should work for all of the cars in these model years though! This actually was part of the reason it is taking so long, these downpipes are hard to get your hands on used!
On the Dyno info, I would love too, but that will be up to the owner to do once he gets his car back. I have taken a before run on my gtech meter to have a general baseline but a dyno would be really nice! I am expecting the downpipe and exhaust will add power range in the lower and upper end on these cars and maybe a slight 2-3whp gain on the downpipe and maybe another 5whp on the exhaust. This may not be that much of a numbers gain but it should increase the power under the curve and really open up more tuning options that do offer power (ie stage 3 tuning ). Toeball on Tdiclub or anyone with a stage 2 tune would be perfect to dyno a before and after just to be sure. As some of you may know these cars pull back fueling at high EGT temps, a stock downpipe will limit power on these engines because of the design; a full downpipe and exhaust system will completely remove that. If you stay out of the fueling after a tune and full exhaust upgrade I also would expect your fuel economy to increase over stock!
EDIT: All set on cars for test fits now unless you have a DSG!
Last edited by shortysclimbin; 12-14-2010 at 07:17 AM.