Interest in 3" exhaust systems and other performance stuff?

[v-dubed]

yea alot of parts had to come off... like my battery is in the back... also power stering lines are in the way... soa re u running the piping under the bumpersuport and rapping over the fog lights?? and dont forget u have a blinker that sticks out 2...

[BoostedOne]

Thats what sucks, is trying to design something for people who dont want to relocate half the car. If I was doing this for myself only, I could have had it done in 1/5th the time and greif.
But yeah, coming from the IC back to the TB, it comes striahgt out, then bends up a bit to get tight to the end of the frame rail, then bends up a bit more(one bend wouldnt work because the bend ended up hitting the turnsignal), then finally bends back under the headlight. You know the rest.
There is like 2.5", maybe 3" of space from side to side between the frame rail and the pocket in the bumper cover for the turn signal. I managed to get the piping to fit up in that little groove.
If I showed a pic, it would seem like the end result was obvious. Not quite so obvious Im sure you know when you are sitting there with a pile of bends, welder, a grinder(to cut the welds back off), etc putting the bumper on and off on and off etc...I never would have thought I would have to do so many little doglegs. You had roughly 500 degrees in bends, but only 6 total bends. Mine has 400 degrees in bends, but 7 bends. So yeah, I got less degrees and more bends. So your original statement was sorta accurate Its alot of 45s.

[Red Rider]

Great info-really enjoying this thread-I also have auto trans and i do want a fmic.

The question I have on fmic is water temp. Will nb run a little hotter.

I am asking this because I have read about some having temp problem with fmic installed. But this could be because of improper installation.

[NJ Turbo]

Yeah this is a great thread!
Sort of listening in as you figure out how to do this.

I'd be very interested in the final product.
I am one that doesn't want to relocate much if anything, but would love a fairly direct piped FMIC install which fits under the stock front.

Keep it up and keep us posted!!

[Grey Ghost]

Originally Posted by BoostedOne

Im wondering what the interest is in a 3" exhaust system for the New Beetle?
Im working on one right now, hopefully to be fully available in about 2 months..

Specs are:

• Fully mandrel bent, no crush bends!
• Flex joint up by the turbo, not down at the bottom like the GHL. Putting the flex down by the cat like GHL does puts more stress on the pipe, increasing the likelihood of a crack.
• Fits in the factory hanger locations
• Pipe will be fully aluminized steel. Its not stainless, but the kit will be half the price of a stainless.
• Available with or without converter. Converter will have a 5yr/50K mile warranty through the manufacturer that covers the converter and replacement charges at a local shop.
• Available with or without muffler. If chosen, muffler is a 3" Magnaflow. I started using these recently on the GTI. The GTI is full 3" with a big turbo, no cat, and not very loud.
• If you get the kit with a cat or muffler, delete pipes will also be included if you want to remove them for racing. Swapping out the converter or muffler section will be a 15 minute job once you jack up the car with this kit!
• The parts will be available seperately(downpipe alone or cat back alone), but I do not garuntee they will be a direct fit to someone elses downpipe. Although these pipes will line up pretty close to the factory system, I do not include adaptors to neck down my 3" system to the factory 2 1/8" system. A local shop could do it pretty easily though.
• Has a turn down style exit just like factory. All you will see from the rear of the car is a little nub pointing down. No bling bling tips. One of the reasons for this is because tips are like wheels, everyone likes something different, and hardly any of them fit exactly the same. All of these systems are made on a jig, so if every tip fits slightly different it means a different mockup and jig for every tip out there. Its alot easier for the guy at a muffler shop or you in your garage to add the perfect tip if you want to show it off.
• Includes new factory OEM gasket(not a cheap chinese knockoff) for use at turbo to downpipe connection.
• Flange at turbo is precision laser cut, 3/8" thick steel. No cheesy 1/4" flanges.
• Uses high quality, easy to assemble stainless steel band clamps. Not cheap, leak prone, pain in the arse to tighten U-bolt style clamps.
• NO CHEAP CHINESE PARTS! The only parts not made right here in the US is the pipe(which is Canadian, and may be changing) and the gasket which Im guessing is German. Even the clamps are American made.

During the design phase the entire system was fitted with no flex section in the down pipe. The flex was finally added after the piping angles were worked out perfectly and jigs could be constructed to duplicate the system exactly every time. Reason I mention this is because some ill fitting assemblies rely on the flex section to make up for improper pipe fitment. The flex is not designed to do that, and will fail prematurely if exepected to do so.

Pricing is looking to be as follows:

• Downpipe, no cat converter: $175ish
• Downpipe, with cat converter, AND cat delete section: $275-300
• Cat back, no muffler: $~300-350
• Cat back with muffler and muffler delete section: $375-425

When looking at the price, also consider the flexibility. Im not aware of any other 3" turbo back systems available for the New Beetle, but if there are I dont think any of them give you the parts and the option to remove the converter(or add them) in 15 to 20 minutes.

I am working feverishly to get the system to production, but it can take 2-4 weeks to get enough parts to do a run of systems and as with any small company there are limited funds. I am trying to avoid thinking I need to get 30 systems made and it takes 2 years to sell them I'm hoping to get the details taken care of, as well as a full revamping of the website to coincide with the release of this product.

Other products I am working on in the near future is a full bolt on front mount intercooler kit for the 1.8T, and billet fuel rails which allow the use of an aftermarket, external, fully adjustable fuel pressure regulator and more common Bosch injectors without using rail spacers.

Normally I wouldnt bother on a post like this, but I know the New Beetle is somewhat of a niche market and probably why it is ignored by the aftermarket when it comes to vehicle specific products. Im just trying to determine if its because of the number of New Beetle turbos compared to GTI and Jetta turbos, or if its because none of the NB owners spend money on serious upgrades.

Thanks,
Scott
Max PSI Racing
www.maxpsiracing.com <--I know the site stinks, the new one is going to be muuuuuuch better!

Will this fit a Turbo "S"

[The Cheat]

Originally Posted by Grey Ghost

Will this fit a Turbo "S"

It should...turboS is the same as the other NB 1.8Ts for exhaust components.

The IC should fit with NO body mods whatsoever I'm guessing. When I mocked up my TS bumper on my TDI, I found that I could shove a ABD core in no prob.

[TechnoTrix'd]

Cool thread. I've been looking for a good OEM IC replacement set-up and the Tyrolsport was the one I liked the best due to OEM fittment. Basically just bolt and go (very minimal cutting with no parts needing to be moved).

As NJ Turbo mentioned, they don't make it NB friendly though...

Hey, if you build it, they will come, with cash!!! TechnoTrix'd..

[BoostedOne]

The water temp thing is a good question and something I look forward to finding out.
Im confident that it wont end up being much of a problem though. The intercooler core has a gap between the core and the AC condensor, meaning that air can move around behind the core.
Also, as mentioned this IS going to require trimming or removal of the bumper bar. If you trim the bare minumum out of the bumper bar, you will obviously cut off airflow to a significant part of the cooler and the radiator. If you leave the bumper bar off, I doubt there will be any kind of issue.

I've been hesitant to give out much info lately while the details get worked out. Like I said, if I was doing these one off in a shop it would be easy, but all this stuff needs to be jig done so that they are all exactly the same, which means building the jigs and so forth. That and other things like getting boxes to get everything in as well as redesigning the website to go with it is takin time.

Considering the size of the cooler, mods to the car though are pretty minimal. The battery stays in the stock location(although it if you trunk mount it, you will get loads of room to do a true cold air intake). The stock air box gets trashed, but the kit will include a K&N cone filter for the air meter and for the air pump, as mentioned the bumper gets modifed or left out, as seen in the pics the radiator trim needs to be trimmed, the grillework needs to be trimmed a bit, and the fog lights will need to be modified if you want to keep them. Yeah, its not a 100% throw it on and go, but on the other hand its still alot easier than what alot of other cars need to be done.

The exhausts are going to be available sooner. I should be inthe last few stages of prototyping now, and then its just a matter of getting the time to produce the production systems. The price on the exhausts is definately well within if not under the predicted price.

So if you are itchin to get this kind of stuff, hit me up and I will let you know where things stand.

[Anaconda]

Any word on the exhaust?

[moved2tdi]

Originally Posted by Anaconda

Any word on the exhaust?

or the intercooler?