Another one! The car park at my new job has nasty speed bumps and this exhaust was catching so phase two was brought in. I bought a single quiet pack exhaust for a type 4 which bolted straight onto my new headers. Unfortunately this was even lower than the stock back box, so this was turned upside down and the muffler cut and turned and now it works great! The pictures below didn't come out very well, the first one shows the stock aftermarket exhaust as I received it, the second how it fits when modified.
It is made up from two pairs of J tubes (designed to replace the heat exchangers on Beetles) which provided all the bends and piping I needed as well as the flanges, which needed a small amount of tweaking to fit the Alfa engine. These make up a pair of headers that join to a flange (cut off another scrap backbox), onto this any type 4 system can be bolted, for the moment I am using a stock backbox which gives a nice finished look to the rear end, but in the future I may try an aftermarket system which will bolt straight on to my new headers. I stripped the headers to bare metal and got some exhaust paint from Halfords which seems up to the job, better than some other products I have used! As a bonus the backbox I got was galvanised (German part) so I gave it a coat of paint just to getrid of some discolourisation.
The old exhaust system was made up of the original Alfa header, which I cut and turned around. Onto this I welded a sectioned, aftermarket Beetle, 4 into 1 header and then a twin quiet pack pair of mufflers.
