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atlas2l8v 03-07-2019 09:30 PM

Subaru beetle exhaust
 
Ive made an exhaust for my beetle subaru using the down pipes from the subaru mated to a hidden beetle exhaust but it hangs down lower than I would like.

Does anyone know of anyone who makes exhausts for subaru bug conversions ?

StuF 03-07-2019 10:28 PM

Give Mike Hausmann of Vintage Volkshaus a shout - he made a perfect exhaust for our EJ25 powered bus that fits with a standard Westie towbar. Amazing craftsman and incredible welder

Suhy 07-07-2019 08:39 PM

Have you tried a STI exhaust manifold?
Apparently, it's a very good fit.

Big Al 22-07-2019 04:20 PM

I just bought all the bits and did it myself, made it up using clamps etc to start and then marked it for welding.

Ive been extending it today actually as want it to exit the stock outlets but not had time to finish before bugjam. Doh.

Mocking up
https://i.ibb.co/L69QWcj/DSC01182.jpg

Complete
https://i.ibb.co/pJFVHNR/DSC01757.jpg

https://i.ibb.co/QX4QV14/09112011711.jpg

Extending today
https://i.ibb.co/tCPg7Qx/20190722-145407.jpg

atlas2l8v 22-07-2019 07:02 PM

Quote:

Originally Posted by Suhy (Post 16552843)
Have you tried a STI exhaust manifold?
Apparently, it's a very good fit.

Ive made mine from the Ej25 manifolds, flexi and a beetle exhaust and it clears speed bumps just bloody noisy


Quote:

Originally Posted by Big Al (Post 16555231)
I just bought all the bits and did it myself, made it up using clamps etc to start and then marked it for welding.

Ive been extending it today actually as want it to exit the stock outlets but not had time to finish before bugjam. Doh.

Mocking up
https://i.ibb.co/L69QWcj/DSC01182.jpg

Complete
https://i.ibb.co/pJFVHNR/DSC01757.jpg

https://i.ibb.co/QX4QV14/09112011711.jpg

Extending today
https://i.ibb.co/tCPg7Qx/20190722-145407.jpg

Looking good fella, ive made mine from a mixture of the EJ25 manifold and pipework with a beetle exhaust but its damned noisey.

StuF 22-07-2019 08:35 PM

Thats one of the positives of my exhaust - its almost silent at idle, nice rasp on acceleration and cruising its quiet again. Drove 200 miles today back from wales and it was effortless on the motorway at 70 mph

atlas2l8v 22-07-2019 09:28 PM

Quote:

Originally Posted by StuF (Post 16555289)
Thats one of the positives of my exhaust - its almost silent at idle, nice rasp on acceleration and cruising its quiet again. Drove 200 miles today back from wales and it was effortless on the motorway at 70 mph

I therefore have exhaust envy :lol: Brilliant i will give him a shout i think.

StuF 22-07-2019 09:54 PM

Quote:

Originally Posted by atlas2l8v (Post 16555301)
I therefore have exhaust envy :lol: Brilliant i will give him a shout i think.



Couple of pics of what Mike was able to make for me - however the backbox is where the magic happens and where the silencer action takes place

https://uploads.tapatalk-cdn.com/201...272550241d.jpg

https://uploads.tapatalk-cdn.com/201...e6ba464f9c.jpg

https://uploads.tapatalk-cdn.com/201...175c9ab9c5.jpg

https://uploads.tapatalk-cdn.com/201...42131683e7.jpg


Sent from my iPhone using Tapatalk

atlas2l8v 22-07-2019 10:20 PM

Quote:

Originally Posted by StuF (Post 16555309)
Couple of pics of what Mike was able to make for me - however the backbox is where the magic happens and where the silencer action takes place

https://uploads.tapatalk-cdn.com/201...272550241d.jpg

https://uploads.tapatalk-cdn.com/201...e6ba464f9c.jpg

https://uploads.tapatalk-cdn.com/201...175c9ab9c5.jpg

https://uploads.tapatalk-cdn.com/201...42131683e7.jpg


Sent from my iPhone using Tapatalk

Thats some nice work...Ive sent him a message. Cheers mate

Big Al 23-07-2019 08:39 PM

That looks a nice exhaust however I don't mean this as a criticism but if looking for maximum bhp it doesn't seem a very well gas flowed solution, much like an original bug box making the exhaust gas do an unmerged full 90 in there??
I'm no expert just saying what I'm seeing so possibly complete balls and he's the expert :lol:
I guess as mine is a turbo the ideal solution may be different as I just need the gas out easy as poss to minimal presume after the turbo. (And I know I'm turning mine 99 degrees but there are x2 3'' outlets!!). However merged bug headers are merged for a reason and the style like that are known for less performance advantages in the bug world are they not?
Maybe it's a toss-up between quiet and performance?

StuF 23-07-2019 10:06 PM

Quote:

Originally Posted by Big Al (Post 16555487)
That looks a nice exhaust however I don't mean this as a criticism but if looking for maximum bhp it doesn't seem a very well gas flowed solution, much like an original bug box making the exhaust gas do an unmerged full 90 in there??
I'm no expert just saying what I'm seeing so possibly complete balls and he's the expert :lol:
I guess as mine is a turbo the ideal solution may be different as I just need the gas out easy as poss to minimal presume after the turbo. (And I know I'm turning mine 99 degrees but there are x2 3'' outlets!!). However merged bug headers are merged for a reason and the style like that are known for less performance advantages in the bug world are they not?
Maybe it's a toss-up between quiet and performance?

Al - its a fair point and something I did ask Mike about after he crafted the exhaust, apparently the headers do merge however it is done inside the large and wide back box which isnt as simple as it would appear. Think it is one of his secrets how he crafts the boxes - they aren't the usual baffle plates and wadding found in some systems.

Ive been out in a few EJ25 powered buses/bugs and mine is no slower or faster than any of the others however is much more civilised than any of the other options I sampled (Fellows, Custom, RJES and mixes in-between of longer/merged/unequal/equal length headers and so on)

Ive the ground clearance required and the wife is happy with the noise when cruising the motorway - even upto some silly (overtaking) speeds

Ill tag Mike in the thread and see if he has anything to add

Stu

Goldfeesh 24-07-2019 03:15 AM

Mine currently is a stock Subaru manifold (Will be shortened at some point) with a motorbike can on the back. Loud. Stupid. Hits the floor a lot. Makes long distances at speed an unpleasant experience. But cost under 20 quid and doesn't hurt the power because I'm basically using no silencer.

Big Al 24-07-2019 10:51 PM

Quote:

Originally Posted by StuF (Post 16555499)
Al - its a fair point and something I did ask Mike about after he crafted the exhaust, apparently the headers do merge however it is done inside the large and wide back box which isnt as simple as it would appear. Think it is one of his secrets how he crafts the boxes - they aren't the usual baffle plates and wadding found in some systems.

Ive been out in a few EJ25 powered buses/bugs and mine is no slower or faster than any of the others however is much more civilised than any of the other options I sampled (Fellows, Custom, RJES and mixes in-between of longer/merged/unequal/equal length headers and so on)

Ive the ground clearance required and the wife is happy with the noise when cruising the motorway - even upto some silly (overtaking) speeds

Ill tag Mike in the thread and see if he has anything to add

Stu

Ahh cunning! I like that :)

Big Al 24-07-2019 11:23 PM

Quote:

Originally Posted by Goldfeesh (Post 16555519)
Mine currently is a stock Subaru manifold (Will be shortened at some point) with a motorbike can on the back. Loud. Stupid. Hits the floor a lot. Makes long distances at speed an unpleasant experience. But cost under 20 quid and doesn't hurt the power because I'm basically using no silencer.

To be fair mine is turbo so the sound is already chopped up, fitted the biggest straight through back box I could find and it's still loud. Unless you playing with something the length of the muffler above or wanting to restrict flow I'm not sure you can do much about it. Again, just an assumption based on limited experience. The turbo mufflers etc on bugs are all very loud too and they are fair sized cans! My JMR low loss turbo style muffler cost me a pair of headlights and a paint job I think due to pissing someone off going to work at 6am in the bug, was no sneaking about :lol:

beelzedub 29-07-2019 10:17 PM

Hey guys its Mike from Vintage Volkshaus here. Thanks Stu for pointing me back in here, its been a long time :lol::lol:

basically as Stu said my headers actually extend into the silencer and merge inside.
i have had experience building exhausts for some of the worlds most expensive and prestige vehicles. i have also been involved with the developement of Jaguars f-type factory exhaust systems as an outside contractor.

all of my vw silencers incorporate a lot of techniques to enable the soundwaves to do all kinds of crazy stuff to help with noise whilest trying not to slow down the exhaust gases too much to aid flow.

the system fitted to Stu's bus was designed to look stock and behave well and having had on eof these on a rolling road found that it does it well.

funny how a lot of subaru conversion guys said one silencer will not work and will be too loud, not if you know what you are doing and actually build exhaust systems knowing the maths and science behind it.

yes in theory the turbo acts as a silencer (by choping it up):lol::lol:
i have sucessfully built a single box straight through on a turbo bus and it wasn't loud. it just depends on who builds it.

Big Al 15-08-2019 11:44 AM

Finally got mine extended. Sure it's not upto the reduced resonance, very sexily welded, definitely not hydrogen enbrittled, chopped up turbo muffled standards of others :p :lol: but I'm happy for a diy job :)

Can't wait to hear it under load, lots hope it doesn't fall off.

https://i.ibb.co/2F9CCgs/20190814-202748.jpg

Has anyone had any experiments adding perforated baffle to theirs much like a stock bug on the exit pipes. Doubt it would do much on mine, maybe reduce the low boom a little? Just curious?

StuF 15-08-2019 01:49 PM

Al - im sure that will sound great, please post a vid of it running when you get chance!! Those tips look epic

eugopnosaj 15-08-2019 04:56 PM

Question: I need to redo mine, but what have you done about the 2 lambda sensors that the ECU needs? I re-used the CAT and put one before, and one after as stock, and then used a S/S centre box (can't remember where it was from) as a back box, its loud doing 70mph but on idle its reasonably quiet.

Big Al 16-08-2019 12:05 PM

Well no took it for a run and it's supprisingly quieter, much quieter in the car. Maybe it's the reduced energy at exit as now spread through 2 pipes, I actually assumed woukd trumpet the sound and make it louder but wrong on that one. Also it's less boomy and low down. Could also help that I'm directing all the sound at the guy losing the race behind me :lol:

Big Al 16-08-2019 12:10 PM

Quote:

Originally Posted by eugopnosaj (Post 16559781)
Question: I need to redo mine, but what have you done about the 2 lambda sensors that the ECU needs? I re-used the CAT and put one before, and one after as stock, and then used a S/S centre box (can't remember where it was from) as a back box, its loud doing 70mph but on idle its reasonably quiet.

Unless I've cocked up I only have the one sensor. This is the one after the turbo. I fitted it same distance from the turbo as the stock downpipe. I don't have a back one at all.

Pic here of mine. Right or wrong :lol:
https://i.ibb.co/g7xrWD3/2013-07-18-...ps2864bc4b.jpg

eugopnosaj 19-08-2019 12:10 PM

Oh right, I'd like to remove the CAT if I don't need it, mine definately has 2 sensors, and the wiring loom diagram notes these too. I wonder if I can delete it and just clear the engine codes, its not like its needed for the MOT. I guess it depends how the ECU reacts to one of them being removed as I'd imagine as one is pre-cat, and the other post it is so the ECU knows what is going on to the gasses etc. I'm not sure!

atlas2l8v 20-08-2019 11:00 AM

The car I used only had one o2 sensor too..

eugopnosaj 21-08-2019 04:31 PM

Mine has a front, and a rear o2 sensor, its in the wiring diagram and if you google it it comes up on diagrams of the exhaust system :confused:

On further googling I found this:

https://forums.nasioc.com/forums/sho....php?t=2410602

Seems the front is 100% needed, but I can remove the one after the CAT when I take it out of the exhaust system. ;)

atlas2l8v 22-08-2019 08:24 AM

Quote:

Originally Posted by eugopnosaj (Post 16560761)
Mine has a front, and a rear o2 sensor, its in the wiring diagram and if you google it it comes up on diagrams of the exhaust system :confused:

On further googling I found this:

https://forums.nasioc.com/forums/sho....php?t=2410602

Seems the front is 100% needed, but I can remove the one after the CAT when I take it out of the exhaust system. ;)

Going to check my pinouts on the wiring incase it was missing, but when i stripped the car it deffo had one sensor and couldnt see a location for another. What fun.

eugopnosaj 22-08-2019 01:46 PM

1 Attachment(s)
This is the wiring for mine *shrug*

Suhy 22-08-2019 10:23 PM

Quote:

Originally Posted by eugopnosaj (Post 16560761)
Mine has a front, and a rear o2 sensor, its in the wiring diagram and if you google it it comes up on diagrams of the exhaust system :confused:

On further googling I found this:

https://forums.nasioc.com/forums/sho....php?t=2410602

Seems the front is 100% needed, but I can remove the one after the CAT when I take it out of the exhaust system. ;)

That's a great piece of information. I have 2 o2 sensors as well. Thanks for bringing that up

Big Al 04-09-2019 11:46 AM

Good link. Dreading plugging my ecu in God knows what will throw up!


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