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Made some progress on the exhaust - I decided on race mufflers for their straight through design but used two (a smaller one after the resonator and a bigger one just before the tail-pipe) to get the sound levels down to where I want them.
Pipe clamps made from two pieces of steel angle and a pair of bar-clamps I had...
Ran just the resonator and small muffler for a while...
Reworked the bends around the differential and got the exhaust a little closer to the exhaust cut out...
Here’s an OEM mid-span bracket that didn’t make it into my parts pile somehow. Might buy one to see if it will work - PN: 8N0253461C...
Stainless hanger positioning at the back muffler was probably the fussiest part of the exhaust fab - have one on each end of the muffler...
Muffler secured in position with tail-pipe centred in the cut out...
Still need to weld in some mid-span hangers and the exhaust tip but it’s getting pretty close. The stainless Torco clamp behind the muffler is pretty lame compared to the OEM sleve-clamps so I’ll swap it out - it doesn’t seal completely and is pretty thin. The exhaust is really close to the CV boot on the driver’s side of the diff so I’ll put some heat wrap on that too.
It’s been a while hey - still have a decent sized to-do list but I’ve been renovating my house and completely neglecting the car. I’ll def post up when I’m back at it though.
Not much of a progress update but I did manage to install some of the interior trim & panels - trunk items need to be trimmed because of the higher floor pan...
Jesus.... I have a pdr guy if you're interested, i only let him touch my car and his price is good too, I hope you didn't report to insurance yet because that doesn't look good at all.
Current Fleet
#ProjectICreate Jetta GLI32
2001 Cobra #88/3786
1989 Jetta Trophy 1 of 500
2004 Audi A2 FSI Colour Storm RHD
2015 B8.5 S4 Sepang/Technik/6MT/SD/AAD/CF
Jesus.... I have a pdr guy if you're interested, i only let him touch my car and his price is good too, I hope you didn't report to insurance yet because that doesn't look good at all.
Thanks for the offer - it is in with insurance already though... the insurance adjuster has bee really good so far but no word yet from their appraiser. I think the plan is to do paintless dent removal through Canadian Dent and then if I need paint it can go to a paint shop. Should find out shortly...
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