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Idea For Custom 1-5/8" Speedster Exhaust

FM Former Member
Well everyone, I've been bouncing the idea of putting together a custom exhaust. The following is what I am considering doing:

Header-I am maybe going to see if I can get an "A-1 Sidewinder 1-5/8" merged header or make my own out of two scrap donor headers.

QUESTION: Who. besides A-1, sells a 1-5/8 sidewinder header? Does A-1 sell the individual header and for how much? My problem is that I am not in Southern California and it is a pain to get my car there.

Using a thick-flange connection, I am thinking of attaching a 2-1/2" "U-BEND" (180-degrees). This bend will go to the right and then turn back around to the left.

Then, using another flange, attach the end to a Magnaflow "Camaro muffler". The Camaro muffler has one side with both an inlet and an outlet and the other end with only one outlet. The dimensions, according to their website, might work with my VS.

The outlets will either come out the rear with two 2-1/2" outlets positioned like the ones of a 356 "Sport Muffler" or maybe be merged together somewhat like a "Sebring" type oval exhaust tip.

I think it might just work. I am going to see if Dynomax, Tiger, or others have a similar muffler.

For heat, I have a hipo 2110-cc performance engine with a 121/125 Webcam, 044 CB heads, 9.5 CR and I am using my own 911 fan shroud design. I routed some of the air to cool my oil and I am also considering routing some air to a custom heat exchanger that will be on one (or maybe both) of the "J-pipes". Luckily for me, my friend owns a fab shop and he is willing to help me out.

So what do you all think?

Regards,
Tony
speedy57tub or LVWOODGOD
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FM Former Member
Well everyone, I've been bouncing the idea of putting together a custom exhaust. The following is what I am considering doing:

Header-I am maybe going to see if I can get an "A-1 Sidewinder 1-5/8" merged header or make my own out of two scrap donor headers.

QUESTION: Who. besides A-1, sells a 1-5/8 sidewinder header? Does A-1 sell the individual header and for how much? My problem is that I am not in Southern California and it is a pain to get my car there.

Using a thick-flange connection, I am thinking of attaching a 2-1/2" "U-BEND" (180-degrees). This bend will go to the right and then turn back around to the left.

Then, using another flange, attach the end to a Magnaflow "Camaro muffler". The Camaro muffler has one side with both an inlet and an outlet and the other end with only one outlet. The dimensions, according to their website, might work with my VS.

The outlets will either come out the rear with two 2-1/2" outlets positioned like the ones of a 356 "Sport Muffler" or maybe be merged together somewhat like a "Sebring" type oval exhaust tip.

I think it might just work. I am going to see if Dynomax, Tiger, or others have a similar muffler.

For heat, I have a hipo 2110-cc performance engine with a 121/125 Webcam, 044 CB heads, 9.5 CR and I am using my own 911 fan shroud design. I routed some of the air to cool my oil and I am also considering routing some air to a custom heat exchanger that will be on one (or maybe both) of the "J-pipes". Luckily for me, my friend owns a fab shop and he is willing to help me out.

So what do you all think?

Regards,
Tony
speedy57tub or LVWOODGOD
FM Former Member
Tony, the A-1 Muffler 1 3/4" "Sidewinder" system on my car had minor fitting issues - the #3 primary tube didn't quite clear the stock tin and had to have a short piece spliced in; that tube's flange was also not quite a good fit at the head so the tube was heated and tweaked for a proper fit. I had asked Tiger (Manuel) to make sure the primaries cleared the thermostat on the right side and that was no problem.

Almost any aftermarket system you buy may have similar minor fitting issues.

I would suggest that you ask him to build you a system with the collecter pointing straight across the crank centerline; mine points slightly forward which made fitting up the muffler pipe a bit of a hassle, but nothing serious. If you get one have him send the muffler and its associated pipes as separate loose parts so you can cut/splice and adapt to fit your specific installation.

I'm not knocking his system - I think it's a great street exhaust using the Dynomax with input and output on the same side of the muffler - fairly quiet and efficient.
FM Former Member
George thanks for your input. I wish I was still in SC so I could easily get my car there. I especially think your suggestion of getting it in sections is a good idea for fitting. All engine dimensions vary and by getting it in sections that should simplify the install. I could even add flanges here and there for a good closed system. BTW, how much do you think the header should cost me.
The Camaro muffler I was looking at was a Magnaflow one which has one outlet on one side and a combination of an outlet and inlet on the other. If the size allows, this can enable me have the muffler at the rear and to have dual tips or a merged single oval tip out the rear of the car. It's all about the muffler and space. What sounds better, the Dynomax or Magnaflow muffler?
Thanks,
Tony
Ron ORon O1984/2010 IM, B.C. Canada
I think that the Magnaflow is a bit louder than the Dynomax. I have a single Magnaflow on my 2110 and it's fairly quiet until I press down and the 'go' pedal...then it gets LOUD (which I like).
Also, the Magnaflow is a bit cheaper than the Dynaflow (both stainless). I'm pricing out a Magnaflow and Dynomax for my 911 pickup (which is similar to the muffler you would use for your set-up) and the Magnaflow was $160, while the Dynomax was $240 (Canadian funds). I'm going with the Magnaflow for my 911pickup.
Ron
FM Former Member
I just got back from my garage. I appears that the 14 to 18 inch mufffler length will be okay. There is about 5-5/8" of an inch of space between the rear apron edge and the header primary pipe for numer four cylinder. Assuming that the space is at least this with the "Sidewinder" header, a 5-inch wide header should work like I am planning. Now if I can only get the header and associated part! Details, details, details.....

Ron, I guess either will work with maybe the Dynomax yielding a "little" more power.

George, did you get the system installed or was it sent to you in pieces?

Regards,
Tony
FM Former Member
Tony, the system was fitted and tweaked at CB Performance, but from the header flange out it was sort of tacked together for testing purposes. While I was in Vancouver earlier this week I discussed final fit with Henry and Kevin and they hooked it up and tacked it together for final welding and ceramic coating. It will have an oval, center exit exhaust pipe like the original 550 Spyders...
Bob: IM S6Bob: IM S62016 Intermeccanica S6 Supporting Member
Well, Ron, all I can do these days is post to this forum. I put my car away for the winter, and of course, the weather has improved, but all I can do is to sit here in front of this monitor, making 'exhaust' noises, and posting relevant comments.

Yes, my wife tells me to stop, but after a few brews, the noises just emanate. I'm getting quite good at it, actually - the noises, not the relevant comments.

Bob
FM Former Member
Thanks everyone!
George, looks like I will go with the same setup as yours. I to want to have an oval sebring/550 exit tip. I am still playing around with the idea of using a Camaro Magnaflow. I will talk to Tiger and see what he thinks. I might just have to trailer my car down there for fitting. BTW, what was the cost for your setup?
Thanks,
Tony
speedy57tub
FM Former Member
Tony. Jim From Stuttgart North East INC. I have a small auto repair shop specializing in porsche and Mercedes-benz only. I need an exhaust system for a customers car.64 Roadster Vin 2N9MW3418RV026255 Control #008993.It's powered by a claudes buggies motor with heater boxes.Can you set me up with an exhaust system better than what it came with please. Email me Thanks Jim
FM Former Member
Jim, Tony, David; this is another Jim, but you can call me Jim Bob. I have a CSP system, the one that has dual 16 1/2 x 5 Mufflers abeam the heads, and uses custom heater boxes, and it exits under the apron with dual pipes. It comes in Stainless steel, and another (lesser priced) with coating. I think it's called a 'Super Performance or Competition System' at the web site under Bug Performace Exhaust.

If that is the system you are looking at, I think it only comes in 1 1/2" Dia... or at least that was the case when I bought the system. But that was a year ago, and I ordered through CSP USA in LA. You may have more options and may find a 1 5/8" system through the German CSP store. I don't know whether they have it in the larger diameter... just offering advice on where to check.

As far as fit... I did some minor heating to fit. But all in all it was an easy fit and exits at the stock VW Sedan Locations, On a VS apron it ends about 1" under the apron and extends even with the apron. We cut 2" diameter chrome extensions and tacked them on the tips so that the chrome extension(s) came out about 1/2" past the bumper and about 1" below the apron.

It's a nice system and looks stock, except it hangs just a wee lower. Hope you can find it in 1 5/8". You'll need that larger diameter for that stroker!
FM Former Member
I just talked with an acquaintance who resides in my hometown and boy am I excited. He is a certified welder and fabricator who does incredible work. I mentioned my problem in that there is no real source out there that makes a custom off the shelf 1-5/8" header and muffler system for our beloved 356 Speedster Replicas. I also mentioned that there are no sources for heater 1-5/8" boxes, roll bars and even turbo headers for our cars. He said no problem and he showed me pics of some incredible header systems he has done and boy was I impressed!

I am going to have him make me a header and muffler combo with heater boxes. Being a mechanical engineer, I am going to design it so it is an "equal-length merged-header system" and the heater box will not be like the stock but different to fit and work with our cars. I am thinking of using either a Dynomax or Magnaflow muffler. The exit options at the moment will be a single Carrera "Sebring type" oval exit or dual pipes. The system can be design with slip connections so that it should be able to be fitted onto any motor with minor effort.

If anyone is interested, email me. I am thinking of possibly making the above mentioned available to fellow Speedster owners. I will use my car as a test vehicle.
D DavesD
Tony,

I read an article recently that talked about building the ideal exhaust system for a given engine.
One of the things it mentioned to consider was the total distance from the velocity stacks to the tail pipe in relation to the various characteristics of the engine i.e. displacement, carbs, cam, etc., and what type of performance you're looking for.
The article claimed that many VW systems are too short to provide maximum output.
If I can re-locate the article, I'll provide you with the link.

Dave
T TUBB
David,
I built an exhaust system for my sprite when I was racing. It required alot of pencil work and figuring but it was based on cam, distance from valves to carb mouth, length and diameter of exhaust pipe, megaphone length, etc. But I can tell you it made the most difference of any single thing I did to the engine. It would just fly between 6K and 8.5k rpm
ed
W Williams
Since we are on exhaust systems, I have a question for the younger members of the forum. I'm sure you all have these small Asian and some domestic peashooters running around with those tomato can mufflers sticking out from under the car. Do they do anything besides making a lot of annoying noise? Add any performance to the car? Hope so because between that and the sub woofers it is very annoying. Guess the old farts back in the 50's said the same about us and our V-8's and smitty's. At least that was a mellow sound, these new ones are like fingernails on a blackboard, maybe I'm just getting old. Question remains to me, are those things adding horsepower or just noise?

Bruce
FM Former Member
Bruce those pea shotters on the current cars do help, on the higher performance version's of some car's. Stick a decent flowing exhaust on a supra or turbo rx-7 and you can see some real gain's. On the civics and the like's with a stock motor 1-4hp gain max, nothing you are ever going to feel.

I had a veilside teardrop on my S2000 for about 3 day's, got about 2 hp but more importantly dropped ~40lb's from the car. Only problem 107 db, ear splitting loud. 9000rpm and the engine sounds like it is going to eat you alive, got pulled over in 18hr's after installing it and sold it to someone else as soon as I could.
FM Former Member
Dave,

I haven't bought an exhaust from John, but have bought other items. My experience with John has been 100% good. He is knowledgeable (see his knowledge series at the site), sells quaility parts, can advise you on particulars, ships promptly, seems like a good guy, and will steer you away on bad purchases or un-needed items. That's my 2 pesos worth.

Jim
No relation to John and no gratuities received :-)
FM Former Member
I've bought parts from John and he is DEFINITELY a great guy and provides great service. As far as the header system is concerned, I do not know if it will meet our intended needs as far as fit is concerned. I wish I knew since if I did, I would already have one of his on my car.
Thanks,
Tony
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