Creating your own Dual Down Pipe.

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Briano1234
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Joined: Mon Mar 21, 2005 5:45 am
What year is your cabby?: 1992
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Creating your own Dual Down Pipe.

Post by Briano1234 »

Creating your own Dual down pipe.

Get thee to a wrecking yard and look for the 4-2 manifold off of a
g60 engine.

Image


At the Pull-a-part, they crimp off the cats and will leave the pipe like
crushed at the 02 bung.


My Muffler guy, and I decided that we would cluge together the down pipe off the
g60.

We cut the down pipe about 1 1/2 to 2 inches below the bellows.
We cut the severly crushed end above the bung.

Image

He expanded the collector end of the dual down to about 1 3/4
We took 2 pieces of 1 1/2 straight pipe, and cut them about 4 inches long.
We expanded the bellows end to accomodate the stub pipe.

We then Used the original down pipe to get the angle that we needed as the down
pipe angles to the right, then sort of comes back to the left.

Do deterime the angles, we just put the single down pipe centered it in the dual.

We attached the collector end and adjusted it.

We welded it together

After attaching the dual down pipe on the car we then took the original down pipe,
and marked it to cut it.

After test fitting it, we drilled a bung hole and welded a Bung to the down pipe on the
right side (passenger) and angled it up a wee bit.

We then welded the down pipe to the original cut piece.

didn't have a camera for a lot of the work.

Started with this:
Image

There is a early Sirrocco dual down pipe for reference.

Here is what we cut out after removing the tin shield.
Image

Here is the best shot of it installed.
Image

Here is the old license plate that I beat into submission, to use as a heat shield
for the Power steering rack. I tie-wrapped it at the top of the rack, then poked
2 holes in the existing shield metal, and use wire coat hangers to wire it off the pipe
at the rear.

It was less than 100 bucks, cheaper than the cost of a new manifold and down pipe from tttuning.
I know as the Green one has one.

The muffler shop charged me 60 bucks to weld it up.
The manifold was 20 bucks at pull a part.

So for 80, I got a nice upgrade, it looks like crap, but I can live with that until
I get ready for a rebuild.
Briano

Yes as matter of fact, I have the Luck o'the Irish...everything I touch turns to fertilizer of the bovine variety.
You can lead a user to a link, but you can't make him Click.... :screwy:
Mikeb52
Posts: 5
Joined: Tue Sep 04, 2012 4:42 pm
What year is your cabby?: 1988
Do you own a Cabriolet?: Yes

Re: Creating your own Dual Down Pipe.

Post by Mikeb52 »

Hi Brian. Good write up..
I have an intact 90 corrado with Its g60 and i was thinking of dropping its 1.8 G into my 88 cabby..
Any experience with this swap or links to somebody elses work would be appreciated. I want to take the engine and harness from the 90 but keep the auto tranny currently in the cabby. I worry about the extra poweer being to much for the tranny and brakes but figure those weaknesses can be adressed with some planning, and help from those more savvy than me.

The Rado was a new project till someone hit me in a parking lot. The insurance company wrote it off so I am replacing it with a 91 but keeping the 90 as well, for parts.

Thanks for any tips .

Cheers, Mike.
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Briano1234
Whats that smell?
Posts: 4105
Joined: Mon Mar 21, 2005 5:45 am
What year is your cabby?: 1992
Do you own a Cabriolet?: No
Location: Duluth, Ga
Contact:

Re: Creating your own Dual Down Pipe.

Post by Briano1234 »

The tranny should work fine as long as you have the 100 mm axles.
Never dropped a larger engine in a car, but have rebuilt a few.
Briano

Yes as matter of fact, I have the Luck o'the Irish...everything I touch turns to fertilizer of the bovine variety.
You can lead a user to a link, but you can't make him Click.... :screwy:
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