Exhaust dimensions for 1g awd

[MattUnderwood]

I'm looking for the blueprints for a 1g awd exhaust full 3 inch. I saw a previous post but it was in 2009 and no one ever answered it. I'm in need to make a full 3 inch and I have the downpipe and muffler with another part from my FWD but now I need the AWD exhaust parts. I would go out and buy a brand new one but money is tight. So if anyone has the dimensions I'd appreciate it. I need the length of the downpipe so I know where to cut the FWD off at, and the straight pipe length that goes from it so I don't have to run a cat. Then the most important thing is I need to know the angles and bends for the last part before the muffler. If anyone has help/advice PLEASE HELP! Thanks

 

[ramsack]

you won't find blueprints to an exhaust. making an exhaust is left to creativity.

 

[99gst_racer]

^^^ Yup.

Climb under the car, evaluate your available space, take some measurements, and build your own design. This method will be 10X easier than trying to replicate something already out there.

 

[LKWTSI]

If it'll help I have my Apexi catless system off my car right now and fully assembled in the shop. I can take a pic and post it if you want and I can mark of distances and such if you want. Either PM me or reply on this thread and I'll get a pic for you in the morning.

 

[MattUnderwood]

A picture won't help and the measurements that are used wouldn't either. I guess does anyone know how long their downpipe was if they made their own, because I'm going to make my own with the pipes I have from my Thermal and the downpipe. I just gotta find a welder and the urge to jack it all up and get under it.

 

[ramsack]

measuring will only help if you are an exhaust shop with a pipe bender and have been making exhausts for decades. it's pretty simple to make an exhaust. just route the piping how the stock one runs and don't let it hit anything. i'm sure once you get into it it will be easier than your preparing for right now.

 

[MattUnderwood]

The funny thing is I don't have the stock one, I have an "aftermarket" one thats just junk. I'm about to go climb under my car at midnight and start seeing what parts I have that work or need to be cut. Thanks again guys for the tips/advice, at least I got an answer from someone.

 

[ramsack]

yikes, that sucks you don't have the stock one to go off of. check out the FAdsmQ section of the forum, there are manuals you can download, and somewhat see how the exhaust routes.

 

[Calan]

The best way to do it is weld it up piece-by-piece using mandrel bends...but it is also time consuming and a royal PITA if you are working on jack stands and no lift.

I bought a DP back exhaust off of someone a couple years ago; it bolted up, but hung too low and banged the underside of the car in a few places. Since it was all made from 3" mandrel bends, I decided to fix it rather than buy a new one.

I ended up cutting it into about 10-12 pieces and putting it back together under the car, one section at a time. Although I NEVER want to be pulling an exhaust in and out from under the car that many times and tack welding in 12" of space over my head again, it ended up fitting like a glove with maximum ground clearance and no banging around.

Whatever you decide to do, it's going to be some work and there isn't much room for error if you want it tucked nicely... especially where it crosses under the rear-diff/axle area. You really need access to a lift if you plan on fabbing one up yourself.

 

[MattUnderwood]

The major thing is I don't have a welder myself only a few friends and I know for a fact they would NOT want to spend an entire day or more going under the car, and back out and then welding etc. I really need to find a way to get a welder.

 

[Calan]

... and I know for a fact they would NOT want to spend an entire day or more going under the car, and back out and then welding etc.

Unfortunately that's really what it's going to take to get it to fit right. It's next to impossible to get the angles correct without tacking up each part of the exhaust in the location it's going to sit under the car. You also need to allow for some bounce as well, so it helps to put everything together in place, trimming pieces as necessary along the way.

FWIW, I use a little 110v Lincoln Electric MIG that I picked up for like $100 or something. It's paid for itself 100 times over in the last 3 years on the car, lawnmower, and countless other things around the house.

 

[MattUnderwood]

Yeah I am getting tired of having to ask a friend's dad if he can weld something for me, and if I could find something like that for dirt cheap it would pay for itself in about a week.

yikes, that sucks you don't have the stock one to go off of. check out the FAdsmQ section of the forum, there are manuals you can download, and somewhat see how the exhaust routes.

Sorry I didn't see you posted twice, but when I got my TSI it had sat under pine trees for at least 2 years, and the previous owner had a full 3 inch custom made exhaust but I didn't get to keep it because my friend who found the car needed it and I don't see him that often. I have a somewhat stock exhaust with the downpipe that is longer than stock and is a lot smaller than stock too.