Exhaust manifold for a 1.8 K-Jet

[Diamond Hell]

the converter put that smaller manifold in there for a reason as he seemed to know his stuff with a full engine replacement.

Hardly.

He had a 1.6D manifold in his hand, as it came off the 1.6D motor he was pillaging for parts like the water flanges etc.  It fitted on the GTI motor and connected to the rest of the awful 1.6D exhaust, so it went on.

Don't presume too much skill or knowledge from that conversion - it pretty much all bolts up.  Not a difficult one to do badly.

[bmouthboyo]

dont suppose you have any links to info on how to do / design that for a T25 bay?

The manifold on there goes to a 4 stud single downpipe, ill try and take measurment when i get old manifold off.

Any ideas of prices to get one fabricated for a gti manifold to a single downpipe thatll fit?

Also how do i go about measuring the curvers etc that i would need?

And lastly what negatives are there from running this engine with a 1.6 manifold? i guess there will be a negative effect in performance but would it also have a knock on effect with gaskets etc ?

Thanks a lot for all the help so far guys.

[Diamond Hell]

And lastly what negatives are there from running this engine with a 1.6 manifold? i guess there will be a negative effect in performance but would it also have a knock on effect with gaskets etc ?

You're strangling it.

Any custom exhaust takes you away from 'default servicing' but with a Golf engine in a T25, as far as most garages are concerned you're a million miles away from standard anyway.

If you change to GTI manifold and downpipe, you can keep to GTI manifold gaskets and GTI downpipe gasket, then if you have a sleeve joint to the silencer you shouldn't have any servicing issues, if it's in a garage.

The actual exhaust pipe (all of about 2-3' of it) HAS to be custom.  A T25 TD silencer will do on the end of your custom downpipe.  This will fit on the standard mounts.

[bmouthboyo]

Thats great so basically if i source a Gti manifold and the top part of a downpipe i can use a sleeve to connect to the existign downpipe and silencer.

This wouldnt require any welding then would it?

Also are those flexi exhaust connection things any good? as these would allow me some play when attatchign it all to the new GTi downpipe.

My main concern is how tight it is in the engine bay, also with a standard gti manifold, wont it sound too loud for the MOT without a center silencer etc.

[Diamond Hell]

It's gonna need welding.

Unless I'm much mistaken there's no noise limit on the MOT test.

The ones I did weren't that loud at all.