Exhaust for my EJ20T

Hey Guys

any ideas for my new exhaust? pics of yours? I want something that will be nice and quiet but of course not restrictive.

my old non turbo motor had the extractors running forward into a big muffler that was under the trannie, then two pipes that went up and threw the engine bay with two little mufflers in the engine bay with pipes exiting just below the boot lid, it was extremely quiet except for the top end and looked great, only problem was after a couple of years the lower muffler has taken a beating
(http://s4.photobucket.com/albums/y134/davidbosa/?action=view&current=9374.jpg)

remember I have irs and also a radiator at the back so there's really no room for a big muffler at the back

also what size and do I really need mandrel bends??

I am about to tackle this as well, but in a buggy so will be a bit different. You going to get it done out of stainless steel or mild steel? I am going to make mine out of stainless. I don't know if anyone sells stainless flanges for the engine/turbo, but am going to draw them up in CAD tonight and get a quote to get them laser cut. 2.5" is a good size for a 2ltr turbo. You don't need mandrel bends, however they are better, less restrictive and look better. The noise is all dependant on the muffler, i've tried a few types on my 2ltr n/a ej20, first one was a reverse flow muffler and it I could hardly hear it. A cheap cannon muffler was loud and raspy, sounded like a quad.. It only lasted 5mins until i had enough. I replaced it with a solid straight through oval muffler, very nice deep rumbling sound, yet not that loud. The turbo will also help in quiting the exhaust down when compared to an n/a motor.

If i go ahead and get some flanges laser cut, i will probably do a few sets (only cost a bit more for a few sets compared to just one). The bends I will buy off the shelf mandrel bends for 45-90-180 bends, and get the exhaust shop to bend up any custom bends i need.

I made mine and the one for the splity out of 3 inch mild steel. You can buy the mandrels in a variety of bends and then just cut them to suit. A triflow muffler is the highest flowing quiet mufflr and costs about $100. It s importand to make a splitter ff the back of the turbo for the best gains. I ca make on if you get stuck as they can be expensive. Mine runs next to the heads and not at the back.
matt

I used 3inch mandrels aswell and just a 2 1/4 hotdog with the stock subie front cut cat with all the shroud taken off and the outlet modified . Heres a shot .

Forgot to take pics of it complete, too keen to get it on the road.

did you weld in a splitter in the mouth...it helps stop the wastegate flow pushing directly into the impeller flow.

see the little piece on this exhaust for the splitty.
http://www.thesamba.com/vw/forum/album_page.php?pic_id=297970

You cna buy stainless steel flanges from either vwrx.com or ebay in US quite cheaply...
Rich