200tdi exhaust options/opinions

[debruiser]

So after a little searching around I haven't come up with a lot on this topic (or it's buried in someones build thread 100000 pages in). I've posted in my build thread (http://www.aulro.com/afvb/members-rides/183428-nicks-1975-series-3-swb.html) but I didn't think that many people would see it (or maybe not many people who know about my question)

So I'm putting a 200tdi in my Series 3 swb. I'm thinking about exhausts now and was wondering what people have used and what works well, on the engine, not necessarily in a series. I read some have used 52mm straight through on a 109, would this be excessively loud on a swb? OR should I go to a 2.5" pipe?

Points to consider:
- I want good low down diesel power
- Turbo to spool quick and easy - reducing lag (I hate turbo lag)
- I'm running a standard S3 gearbox and high speed transfer, sals rear diff with locker.
- Chasing good fuel economy.
- Max db level is - don't be louder than a v8 cruiser :p seriously not too loud but lots of turbo noise is ok :D and I don't mind it making some noise... after all it is a series and if it was quiet I might as well just drive my D90!

I had thought maybe put in a 2 or 2.5" straight through, then see how loud it is and if it's too loud put in a hotdog or small muffler. The car isn't registered (and doesn't have an exhaust) so I can't drive it to the shop to get one made up. I was thinking of possibly buying some bend pieces and welding up my own OR maybe maybe maybe buying a pipe bender... I doubt the bender will happen. It's that or hire a trailer to take it to a 'professional' to make one up. I haven't seen a kit online and a standard exhaust from a 200tdi 90 wouldn't fit would it????

All opinions and experience gratefully taken on board.

[omy130]

Just last week, got exhaust made for my 200Tdi 110 as it was all original. Did all the same searching as you must have and came up with the following plan.

We fitted a 3" with smooth standard muffler shop bends (large as radius as possible where we could), big flow through muffler with a flex joint before the muffler. At the ugly dump pipe, it was slightly smaller but the exhaust shop flanged it out to 3" very quickly.

Results: It's revs easier & higher in gear (probably old exhaust was crap). Turbo spools a little lower & feels it has a bit more torque.

Sound: Beautiful turbo spool low in revs. A bit louder in the cab overall, but a nice sound. No where near as loud as a straight through (I had a 2 1/2" straight through on my 300Tdi for a while, yuk). Just put my mud tyres back on so extra noise doesn't matter.

Recommend it? YES.

Cost: $750.

Car is currently at MR Auto getting the performance tweak/tune. I have fitted an Allisport Double core intercooler. Can't wait to get it back :D

[debruiser]

At $750 i'm assuming it's just a mild steel job? 3" wow.... I was reading on other sites that on Navara's and prados etc some people don't use a 3" cause they deem it too big for the 3L engine. they were talking about 2.5" and 2.75", I started having a look around for bits of 2.75" bends etc but they seem to be pretty thin on the ground.

I really want to get this right the first time because it's a fair whack of money to spend and it's not something that will wear out quickly.

I've also opted for a bigger intercooler than the defender unit. Couldn't justify the $1000 for an allisport so I got a generic one of fleebay, pretty much the biggest one I could find that would fit, single sided 3". Going to put it in front of the radiator with a 14" thermo fan bolted to it. I was going to use one for a XR6 turbo falcon, but it JUST won't fit where I want it to go, could do it if I backed down on my placement of stuff but wheres the fun in that!

[Cammo]

My 200tdi 110 ute was treated to a 2.5" straight through. All mandrel bent. One straight through "muffler" in the middle. With mud tyres at speed it hardly sounded different from inside. Spooled up quicker, revved freer, improved midrange, better fuel economy. Turbo dump pipe was a work of art considering the position. 3" would've been fun to try and route through the same path. I think it cost me 600 bucks about 6 years ago. Only went with mild steel as I didnt intend to keep the truck long enough to get the benefits out of a stainless one.

[debruiser]

My 200tdi 110 ute was treated to a 2.5" straight through. All mandrel bent. One straight through "muffler" in the middle. With mud tyres at speed it hardly sounded different from inside. Spooled up quicker, revved freer, improved midrange, better fuel economy. Turbo dump pipe was a work of art considering the position. 3" would've been fun to try and route through the same path. I think it cost me 600 bucks about 6 years ago. Only went with mild steel as I didnt intend to keep the truck long enough to get the benefits out of a stainless one.

Do you think you could get a pic of the dump pipe route? It doesn't look that scary for my series truck.... just straight down, but maybe I'm missing something.

2nd question - is there something special about dump pipes? ie. are they thicker metal, or different metal?

[Cammo]

Debruiser,
Unfortunately I no longer have the 200Tdi. IIRC, the turbo sat fairly high, quite near to the rear of the engine bay. It meant the bend off the back of the turbo was more than 90* and rather tight.
Regarding your series, my thoughts are perhaps the firewall is different, the engine further forward, or your manifold is different (discovery maybe - if they were different?)

Not sure if dump pipes are thicker, might depend on application.

[debruiser]

I've got a 200tdi from a disco, with a defender turbo on it, so it's up nice and high. I've got the little turned down pipe on the back of th turbo, and yes it is more than a 90deg bend.

[Wal Rat]

I ran straight thru 3" mandrel with only a very small straight thru muffler behind the rear wheels Not a big increase in noise but improvements in all other ways.
Big drop in cabin floor temp:D