So I've seen it around a lot and being asked a lot and no one has the answer. Well a good mate has a 1.4 tdi and wanted a straight through so. We set about doing it yesterday.

What will u need.

50mm o/d steel pipe any motor factors or exhaust shop will have pipe I paid 11 quid for a metre.

Selection of grinding wheels to prep surfaces make sure u remove all the coating of new pipe or will make welding horrible.

A hacksaw to cut pipe.

A welder or know someone with a welder who will do it for beer money or if it's me I like lunch.

U will also need a tip if u straight pipe the back box we got one from halfords but I would get one of eBay would be cheaper make sure it's 50mm I/d and one that points down so the smell emissions and smoke doant go up into the vents just above the bumper.

U may also want a turbo to down pipe gasket we re sealed with exhaust paste and is fine.

So u need to get the exhaust of 4 bolts on the turbo to remove down pipe bit fiddle and I would soak em on wd40 to start with. Didn't get any pictures of this bit as was nice and easy. Once undone it drops out the bottom obviously split it from centre sections first and support the cat one split or u will risk damaging the flexing.

Right now u have it of u need to make a mark at the end of the long weld that runs along the length of the cat so u can line up before welding back up know u can get you are hacksaw and cut the centre of the cat on the inside of the main welds didn't get a before pictures but will be clear soon enough.

Once u have cut the centre out u can see why it's worth doing and how restrictive they are. So now u have to end caps of the cat u need to clean the join up and weld it back together making sure them marks u made earlier line up this is important as the cat exit hole is an inch higher than the entrance hence y u can't just weld a straight pipe in there. U will also need to add a length of pipe to extend the cat section to the centre join

So the cats now straight threw and has been lengthen to join the centre section if that all u wanted then refit and enjoy a few extra ponies under the hood if u want a bit of noise the go on to remove the centre silencer this is a lot more straight forward. Cut the silencer out to then measure the length of silencer and cut some pipe the same length. U should now have 3 pieces looking like this

Now just weld em together nice and easy just make sure u clean surfaces well u will now have a complete centre section

We also removed the back box and made a straight pipe there as well didn't get any pics of this part as was getting late I wouldn't suggest doing the back box it's a bit tricker as u have to weld on new mounts.

That's about it u know have a straight piped tdi it doesn't sound bad if I'm honest as for performance gains ask the only I'm sure he will comment but after the short test drive it made a huge diffence we also fitted an egr delete at the same time. Will do a separate right up for that one. This makes for a nice 2 inch system for under 50 quid if u can weld you are self

you are car will fail mot because the cat has clearly been tampered with emissions will be a lot closer but should still pass, there's no sensors on the cat hence y it's doable.

This is why it's worth doing u can see how it's fairly blocked up the car is around 100,000

Hey did you have any trouble taking the resonator out as iv looked at taking it out but where it exits there is a bend very close to it. I think it would be very hard to get the tube around it and get a good weld.

This was actually my car we did this on, got a good weld on it no problem

This was actually my car we did this on, got a good weld on it no problem

okay thanks for that. I didn't want to cut it to then find out i couldn't get a good weld. Il have a go next weekend. Do you think 47mm internal dia will be okay with a bit of per force

We used 2" pipe think that works out about 51mm. Just try to cut it as close to the silencer your removing as possible so the straightness of the pipe is there to latch onto

okay thanks for that. I'm going to keep the back box on and see what it sounds like. how bad is the drone on your straight though set up?

Yeah I would say try it with backbox still on first, I just went full on straight through but have been toying with putting backbox back on.

Errm to be honest like all exhausts it drones and is a little annoying but just tend to have a bit of music on and ignore it. Sounds like a tank though! Would definately recommend a EGR delet to go with as well!

If u don't take out the cat there will be no sound difference. The centre silencer really don't do much the cat is the main silencer on these and of course the benefits bhp wise

Any Ideas on emissions for MOT? I know these are low to begin with, but combined with an EGR delte do you find it any worse as far as emissions testing for MOT is concerned?

emissions are fine on mine, passed MOT after I did it

Cheers bud. This will have to be done on mine I think,

The EGR delete. Did you just put in a blanking plate or did you buy an Allard kit?

Edited 14 January, 201511 yr by Monkey-man

I bought the kit from "darkside developments" very good diesel tuning place, you may or may not have seen there yellow Lupo Tdi at Santa pod that's is horrendously quick!

Think it was about £50 for the kit, just is a blank and a pipe. Only thing you will notice if you do this is when you switch the engine off its a bit more "violent" as the EGR has a flap in if that when you switch car off it does it slow so the engine doesn't shake so much. It shakes a bit once the EGR is gone but causes no issues

I bought the kit from "darkside developments" very good diesel tuning place, you may or may not have seen there yellow Lupo Tdi at Santa pod that's is horrendously quick!

Think it was about £50 for the kit, just is a blank and a pipe. Only thing you will notice if you do this is when you switch the engine off its a bit more "violent" as the EGR has a flap in if that when you switch car off it does it slow so the engine doesn't shake so much. It shakes a bit once the EGR is gone but causes no issues

Yep i got the darkside egr delete on it now. but it seems like its leaking because there is a small about of oil sprayed over it. seems like i'm having trouble sealing it properly. iv put the large o-ring that is supplied in the grove that seals on the cast part. is that right?

If u have oil in your intake u need to find where its coming from won't be nothing to do with sealing turbo seals failing?

If u have oil in your intake u need to find where its coming from won't be nothing to do with sealing turbo seals failing?

yea il have a look into lit at the weekend

Has anyone got a link for the EGR delete kit please? Thanks in advance!!

http://www.allardaluminiumproducts.co.uk/air-systems/egr-delete-kits/egr-delete-56.html

http://www.darksidedevelopments.co.uk/products/darkside-1-9-8v-tdi-pd130-egr-delete-race-pipe-51mm.html

http://www.darksidedevelopments.co.uk/products/darkside-1-9-8v-tdi-pd130-pd150-egr-delete-race-pipe-57mm.html

While these are for the Mk4 Golf GT TDI. These will fit your polo.

I would stick to the top two however, the larger diameter on the third link is a little excessive but will still fit.

Cheers buddy!!