Hi Polo People. Hope you're all safe and well. 

Hoping to get some guidance on my exhaust. I'm looking to change some parts as i think it's the wrong exhaust. The rear section at the very least. Pretty sure that's from later polo with larger fuel tank and later/cage handbrake setup. 

 

Questions i have are:

Do i NEED to have a flexi section? Previous owner fitted a straight section of pipe between downpipe and rear box. it sounds great but if it is going to cause problems later on, i'd rather swap it out. If it isn't an issue, i'll leave it.

What is the optimum ID pipe to use for 1043cc, (gl) engine? Stock apart from weber carb and electronic ignition. Current setup is 1" ID, all the way through. 

I'm watching a back box that i'm pretty sure is the right one on fleabay. 

 

https://www.ebay.co.uk/itm/254323317021

 But the angle of the pipe that connects to the mid section is different to the one i have in place. 

I've sent a message to the seller, hoping to get confirmation. 

 

The one i have looks like this: 

https://www.ebay.co.uk/itm/264422958691

Which is listed as 1985 onwards.

 

My engine does lose a little power at very high revs, (uphill, 4th gear, anything above 60mph,) from what i've read, adjusting the exhaust MAY help with this. 

 

Just as a side note, i've been considering fitting a cherry bomb back box for a very long time. IF, i were to go down that route, would that cause any issues? Would it have any adverse affect on how it runs? I've looked at videos on youtube but obviously can't really hear it accurately. 

 

Thanks for stopping by. If you are able to leave any xp, that would be appreciated. Keep safe. 

 

 

 

What year is your Breadvan?

 

My 1989 1043 HZ Non-Cat version has the following standard exhaust components fitted, so I would have thought yours shouldn’t be too much different. However, it might be year/chassis number dependant, so take this just as a guide.

 

Front Pipe VW69E (GVW069)

Flexi Pipe VW70D (GVW070)

Middle Pipe/box  VW192 (GVW192)

Rear Pipe/box VW193C (GVW193)

 

With regard to those fleabay items, I ‘d be a bit vary of that seller, as they aren’t describing those items correctly.

 

The first eBay link is actually for a later Polo exhaust. GVW331 is a GT Exhausts part number and can be cross referenced in their catalogue to the later 1994 onwards Polo, so is no use to a Breadvan.

 

https://www.gtexhausts.co.uk/catalogsearch/result/?q=GVW331

 

The 2nd eBay link showing it as after 85, is actually the MK2f Cat Version 1990-92, and again is different to the non-cat exhaust on the Breadvan.

 

https://www.gtexhausts.co.uk/catalogsearch/result/?q=GVW248

 

Have a look in their catalogue, it might help you work out what’s been fitted previously and what should be fitted now.

Edited 3 January, 20215 yr by mk2tastic

Yes, you need a flexi.

 

The engine rocks forwards and backwards on its rubber mounts as drive is transferred through gearbox to front wheels.

 

I used this sort of flexible pipe for a while with a stainless manifold and even so it only lasted about 12 to 18 months. I bought a 2 meter piece and used 40cm, replacing each time it split (or once when it hit road debris as lowered 60mm). One memorable pass-with-a-grumble MOT advisory was 'homemade exhaust'.

 

26mm internal diameter (inch rounded up) sounds about right for 1 litre engine at 45bhp.

 

https://www.mk5cortinaestate.co.uk/calculator5.php

 

 

Mine is 1983, early one. Smaller fuel tank, pulley system on handbrake instead of cage thingy on the rear axle, GL engine code.

The second one is pretty much what i have on it at the moment. No flexi pipe anywhere, just straight pipe from front to back. 

If i leave it as straight pipework, will that have an adverse affect on engine mounts, exhaust rubbers, clamps and other stuff? 

 

In the description for both of those items, it is copied and pasted, but they recommend comtacting them first with make, model, year, reg so they can advise. I have messaged them but being early into 2021, not heard back just yet. 

 

That's the only part i have my eye on at this point unless one of the Polo Wizards on here can point me somewhere else. 

 

Went on 7zap, (mobile interwebs, not desktop,) and the links i got came up as £230 and up just for the rear silencer. If that's genuinely what i'm looking at, i'm thinking custom work may be an option. 

17 minutes ago, dvderlm said:

Yes, you need a flexi.

 

The engine rocks forwards and backwards on its rubber mounts as drive is transferred through gearbox to front wheels.

 

I used this sort of flexible pipe for a while with a stainless manifold and even so it only lasted about 12 to 18 months. I bought a 2 meter piece and used 40cm, replacing each time it split (or once when it hit road debris as lowered 60mm). One memorable pass-with-a-grumble MOT advisory was 'homemade exhaust'.

 

26mm internal diameter (inch rounded up) sounds about right for 1 litre engine at 45bhp.

 

https://www.mk5cortinaestate.co.uk/calculator5.php

 

 

Thanks dude. 

Thought that would be the case. Hopefully won't haven done too much of a number on the engine mounts or anywhere else. 

 

I've started looking for flexi sections already. Just needed to make sure i'm getting the right size. 

 

Mine is lowered on H&R cup kit. Still got spacers on the rear as the exhaust hangs too low to take them off.... yet! 

 

Okay. After just over an hour, flicking between 7zap, google and German ebay, i found this: 

https://www.ebay.de/itm/184293299921

It does say GT and G40 in the listing. I think the G40 exhaust had to clear the supercharger, (anyone confirm please?) I'm only interested in the middle and rear section listed here. Can i use those parts? 

 

I did find some other potential back boxesm in Germany. I'm going back on there tomorrow to see if anything else pops up.

 

I checked the GT exhaust website. Found it a little confusing. Possibly as i was using my mobile. Found listings for what looks like my whip, but i couldn't get any pictures or prices. Again, will try tomorrow on desktop and with slightly fresher head. 

 

 

generic pic on that auction...not even sure there was an 81-84 g40 , the cast manifold needs to clear the supercharger but a g40 system is just slightly larger bore 

 

later cars all had the flexi so someone thought it was a good idea...something has to have some give in it , look how much the engine rocks 

The GT exhausts catalogue is a bit awkward, unless you know the part numbers, so try the Bosal catalogue, it’s a bit more helpful, and also references VW part Nos..

 

http://www.bosal.com/en/catalog/welcome

 

The 1st attached screenshot looks to show what would have been fitted at production, a solid long front pipe without flexi or mid box. However, as others have mentioned a flexi is needed to allow the system to flex when the engine ‘twists’ under acceleration or deceleration.This was probably added as a ‘mod’ on later production vehicles.I’m guessing the lack of a flexi pipe on the early exhausts was probably causing cracking of the exhaust system or the even the manifold, hence why VW changed the design.The latest HZ exhaust system is in the 2nd screenshot.

 

There was never a need for flexi pipes in the old ‘in line’ engine design of many cars, it only became an issue with transverse engine and front wheel drive designs that started to appear in the mid to late 70’s.

 

Is your back box secured to the body by two rubber doughnuts on one hanger, as in the screenshots?

 

If you have the solid front pipe it seems it’s impossible to source, so you may have to go with the later design, unless you can find an exhaust fabricator, which I know isn’t cheap.

 

If you want to keep the front pipe the rear box needs to match it. I doubt that the later rear box can fit the long front pipe.

Edited 4 January, 20215 yr by mk2tastic

@steveo:

Does that mean i can use that G40 exhaust if i can't find the correct parts? I have read that a later/larger manifold helps the engine breath a little better at higher revs, would the larger bore in the exhaust help towards that or hinder it as the exhaust pressure would be less? 

 

@mk2tastic:

I had another breadvan before this one, B reg, that one had the cage/box style handbrake setup, bigger splines on the windscreen wiper mech, but also had flexi mid section on the exhaust. Didn't have centre silencer though. I did get a message back from Heritage VW who said the corrugated pipe they list for 1.0 and 1.3 Golf, is also the correct part for the 1983 polo. So i seem to be getting somewhere. 

My current backbox is secured with rubbers under the rear bumper, but those rubbers and the front clamp at the downpipe are the only points the exhaust is connected to the car. So feel like i kinda need to get on it. 

Thanks for guidance chaps. Much appreciated.

There should also be a mounting point on the body in the region of the handbrake/gear lever, also a strap in the region of the RH driveshaft, that also attaches to the body.There definitely is on the later version. The Bosal Catalogue picture does seem to show that they should also exist on the long earlier type front pipe.

 

So that’s 3 mounting points that should be there.If there’s only one then that is a recipient for disaster if the rear rear mount were to become detached. I think it is also an MOT failure point, if there are missing exhaust mountings.

 

Having the right number of mounting points available would also give you the scope for fitting the later exhaust with the flexi pipe/ mid box if need be, as they are essential to support the extra weight and prevent excess strain/fatigue on the exhaust system.

Edited 4 January, 20215 yr by mk2tastic

yeah g40 system will work...what manifold/downpipe do you have or plan to have?  it will most likley need a sleeve /adaptor to sort out the diameter difference

 

mate runs a ebay manifold n g40 system on his...sounds good 

 

id consider the flexi a later update /upgrade ...dont worry about adding one if you find an affordable system

I did some work on the fuel system towards end of last year and don't remember seeing anything. I do have a couple of universal hangers in my shed that i can put on if it turns out there actually isn't anything there. I'm pretty sure there isn't but i will get under it next couple days to be sure. Never actually made a point of checking that out as it's never come up. On MOT or otherwise. Only advisories were chip in windscreen but i had that replaced through insurance last year so sailed through. 

 

At this point, i'm looking to keep the stock manifold but will keep an eye out for a later one, (think HZ is a good one to look for,) as a bit more freedom in the upper revs would be nice. When we're actually allowed to go out again anyway. Finding a reducer shouldn't be an issue if i need one. 

 

I've seen small sections of flexi that i could consider splicing into the system. 

 

Will start with trying to find correct back box and go from there. If i can find one, will work backwards from that.

 

That one in the diagram above seems like a strong contender. That part number was one of the ones that came up on 7zap. That setup had flexi pipe though. Not straight pipe like the one above.

 

https://volkswagen.7zap.com/en/rdw/polo+derby+vento-ind/po/1983-9/2/253-25000/

 

Part number 9 on that page.

 

I'm lying!!! The front section has that mount with a bolt hole on it. But it wasn't attached to anything until i popped a bolt on it at some point last year. I just need to check that mid section to make sure that's secured. 

https://www.ebay.co.uk/itm/VW-Polo-80-86C-1-0-1-3-1-4-D-Bj-85-94-Auspuffanlage-Auspuff-Montagesatz/173660845737?hash=item286efe36a9:g:VkoAAOSwWSlb-9vI

 

this mk2f style flexi is less restrictive and easier to find

 

id grab something like that....when we was in the eu you could get a whole system from pound for about 60-70£

I saw quite a few parts like that on German ebay the other night. Also found rear and mid box. 

https://www.ebay.de/itm/184293299921

Maybe i should get a German pen-friend. And maybe learn German.

yeah search polo 86c auspuff ....watch out alot are spamming the listing with fits all 1.0-g40....while it kinda does fit all theyre not all the same part /diameter

Thank you. I did try searching that the other night. LOTS of results. A few variations but quite a lot of each one. 

I've sent a message to the seller of the one i've linked above. As it says GT AND G40, i'm guessing the internal diameter is going to be larger than the 25-26mm recommended? 

 

Both sellers i messaged in UK have so far come back as no parts available for my car. Probably why there's the later back box on it now. 

When you said you have a buddy running an "ebay manifold" and G40 exhaust, would you mind elaborating on that? Is it just a mk2/f manifold?

like this - many all over ebay etc for £100 upwards , all same make different price  , dont really fit that great ....fits all mk2 /mk2f cars  

 

https://www.ebay.co.uk/itm/Stainless-Steel-Exhaust-Manifold-Header-Fit-VW-Polo-86C-86C2F-74-94/222641240558?hash=item33d673b9ee:g:3SUAAOSw2AFZtfzA

Edited 5 January, 20215 yr by steveo3002

I've seen those before. I checked a couple out but the listings said they weren't road legal. So i never really looked further than that. 

Thank you. I'll take that into consideration. 

Heard back from German seller, same reply. They don't stock the correct part for my breadvan. 

 

https://www.eurocarparts.com/p/klarius-rear-silencer-705441461

 

This is the back box i have now. Connected to the straight pipe in the diagram above. 

I can find a back box with the part number listed on that diagram, 

861253609, but if i add the c on the end, goes a bit Pete Tong. 

 

Going to see if the part without the C is the correct ID. If it fits, and i don't have any luck with Bosal, may look at getting that.

This claims to be GL backbox for 1983 model

 

https://www.onlineautomotive.co.uk/car-parts/Volkswagen/Polo/1.0L/Petrol/Premium/Exhausts/Exhaust-Back-Box/VKW6063/1/35

It certainly does! I've pinged an enquiry off to them, also to two other places that may stock the right one. Fingers crossed. Thanks dudes.

Found the Bosal, (105-941,) actually found 5 in Germany but the seller currently doesn't ship to UK so bang goes that plan. 

I went back to euro car parts website. I wanted to rule out what i already have in place but got very confused. 

The back box listed on Euro for my breadvan, which i know is the wrong one anyway, is the Klarius VW242E.

The picture matches what i have on my breadvan at the moment but that back box has the part number VW60T. According to a search i did for that part number, it should look like the straighter one in the lower diagram. But it doesn't. Neither one matches in a google search. The VW242E looks like the VW60T and vice versa! 

I know the one i have, (VW60T,) is the wrong one. I have also messaged some sellers before about the VW60T who said it is the wrong part. Think i'm gonna steer clear of Klarius. They twist my melon man! 

 

I did find this: 

https://www.ebay.de/itm/124129056494

The part numbers match! It looks like it will be a better fit too. The Klarius i have is just over 1.5m long and the angle of the pipe where it connects to the mid section pushes the whole mid section downwards. That one linked above looks like a straighter line, while still clearing the rear axle. If i need a reducer sleeve, i can pick one of those up. So i'm gonna jump on this one and see how that goes.

 

Will be looking for a small section of flexi to splice in too. 

 

 

Not heard back from any other sellers yet. We are all grounded though so not understandable.

 

So that part arrived from Germany. Fits beautifully! Has only really pulled the lowest part of the exhaust up by about 3mm. At least it isn't any lower! It's also quiet. Really quiet. Which i'm okay with. Not really noticed any difference in the drive at this point. Still not much go at higher revs in high gear but it does get there and is still quicker than walking. 

There is a hanger in place on the mid section. Seems to be in decent state too so will leave that alpne. 

Will look at flexi section next. 

Never heard back from Bosal or the other places i contacted. But we are meant to be staying home so probly why. 

One last thing, should i pop some gun gum or anything at all where i just fitted the back box? Seems okay. Can see a real small gap between the two sections but i can't see any signs of anything come out of it.