The Hartmann Motorsports Downpipe, originally imported by a very nice German friend of mine direct from der Fatherland, originally came designed to fit an A2 Turbo-Diesel. Since I had an A1, there was a mismatch where the outlet was - in fact it would have poked right through my firewall if I didn't cut it off like so.

The secondary, smaller hole on the bottom is an exhaust system just for the wastegate. I designed it myself to increase wastegate efficiency and to cut down on "boost creep". This is desirable for a modified boost control system, although the autocrossing class I found I am participating in (SCCA Street Prepared) does not allow modifications to the wastegate itself or any of it's boost control system. It's the perfect setup for a high-boost street TD though. :) To fabricate the flange, I did a rough oxy-acetylene flame-cut then dressed up the edges with a dremel tool. I used smaller-diameter mandrel bent 304 stainless to merge the two exhaust flows together smoothly.

Here I have actually completed all the welding. Notice the outlet in place, this is the modification allowing the downpipe to fit an A1. In case you were curious, the tubing is some 300 series stainless (containing nickel and being nonmagnetic, or in other words "the good stuff.") The thick flange and mounting bracket are mild steel. You may be wondering what welding process I used. Believe it or not, I used an oxy-acetylene torch. It's a natural on mild steel, and on stainless I use a backing flux to prevent "inclusions", or impurities from oxidation, interfering with the molten metal flow. The result is the nice beads you see that look like the work of a TIG! :)

I decided I wanted a lifetime long downpipe (the non-stainless parts around my welds would eventually corrode.) Also to prevent excess heat from being radiated into the shift linkage, I decided on having the piece ceramic coated.

Here are some pictures of the completed downpipe with it's handsome coating of "cast iron gray" ceramic stuff (both inside and out.) It not only looks great, but it flows a ton better than the stock cast-iron piece and is a lot cooler! (I've discovered that the new downpipe is cool enough to touch even after loaded operation!)

The thin-walled (I think it's about 16 gauge) tubing of the downpipe lets through a little turbine-whine directly through the engine compartment. I think it sounds really cool, like a big rig. It's not loud enough that it's obnoxious at any time. The downpipe maintains an inside diameter of approx 2 5/16" (some standard metric tubing size probably) all the way to the end, where it enlarges to about 2.5".

Well, everyone seems to have their own tool to deal with those VW downpipe spring clamps. This is what I use. It's made from a monkey wrench with a sharpie, some patience, and a grinder.

Finally, here is the item I fabricated to accompany the beautiful Hartmann downpipe. I decided I should use none less than 304 mandrel-bent stainless steel. I discovered that the lower portion of the "ball joint" in the stock VW exhaust is 300 series stainless so I re-used it! (After boring out the hole to about 2.5" of course! ;)

Tail