Type 4 Exhausts

Pancake | Type 3

This page was last updated Friday, May 18, 2007

Pancake cooling

Here we are going to look at the exhaust systems for the VWs that came with the Type 4 originally, like the 411, 412, 1972-1979 Transporter, and 1980-1983 Vanagon. All of these engines were installed as a rear engine location with a pancake cooling system. We will also look at some off road exhaust systems that work with the stock cooling in an open bay vehicle.

    Street: Let's start by looking at the combination of the stock cooling system and a stock body.

The stock muffler is the obvious first choice. This system was how VW equipped the car initially, but from a performance standpoint, it leaves a lot to be desired. This is especially so if you change camshafts, intake system, etc., or if you increase the displacement of your engine with a big bore kit and/or a long throw stroke crankshaft.

EMPI is one of many companies that offer a 2-tip system for the Bus and VW 411/412

The first aftermarket system is what many suppliers sell called a Monza exhaust system. Though many people find it attractive with two large chrome exhaust tips, it's not the most desirable. This system basically has short pipes that dump the exhaust fumes into two muffler, which each have a chrome exhaust tip.

The Type 1 equivalent of this exhaust system (four tip or GTwas found to flow as well as a stock muffler. Since this system is not a header (or extractor), this system is not the best decision if you've made modifications to your Type 4. Get the Bus header listed below to get the most from your engine.

Systems like this have long been a staple of the Type 4 performance scene.

The best place to get an exhaust system for this application is CB Performance, a Bugpack dealer or Mr. Bug (EMPI) dealer. They offer them in many different applications and are reasonably priced. The only thing I wish they'd offer would be a stainless steel option. Exhaust systems made of stainless tubing don't rust and maintain a better appearance. They typically last years longer than the commonly used mild steel tubing.

It becomes obvious that as you increase the power of your engine, you'll want to run larger diameter tubing for the exhaust system.

BAS of Germany offers this nice Bus system to get the power for your Bus.

On the other side of the Atlantic, in Germany, BAS Ahnendorp offers one of their headers for the Bus. It bolts up to the later model dual port Bus heater boxes with stainless tubes and aluminum-coated silencer. A lower cost version is offered with plain steel tubes also. This system and the Tangerine SuperHeader are your only real options if you have a highly tuned engine in a Bus/Vanagon or 411/412.

    Offroad: In this application, there is only one option. It is available from European Motorworks (They don't have any T4 stuff yet online) and is only available with a stinger (megaphone). The exhaust is only usable with a rear engine sand rail, as the exhaust pipes are routed towards the transaxle bell housing, up alongside the bell housing, and come together at a collector located above the engine. The megaphone exits above the fan shroud. I will see if I can get a picture or illustration of this unique exhaust system. It is available directly from European Motorworks or from FAT Performance.

Type 3

If you are looking to do the Type 4 conversion for your Type 3 (Notchback, Squareback, Fastback, or Type 343 Karmann Ghia), these are the exhaust systems to be looking at. I cover this subject in more detail in my technical article on installing a Type 4 in a Type 3.

The first option is to modify the stock Type 4 muffler and heater boxes. Fabrication of the components will probably be required, but if you have the skills and are building a really mild engine, this might suit you.

Until recently there were no options in a specific header for this conversion. But that has changed. Two manufacturers are now offering exhaust systems that fit nicely in the Type 3.

The American option is the SuperHeader from Tangerine Racing. Although it wasn't designed for this conversion, Jake Raby has reported that the header will work on a Type 3

The UK's Turbo Thomas offers one of the few headers for those Type 3 owners with a Type 4 engine. This header, along with one of their mufflers, makes a great exhaust for your Type 3.

The other header comes from the UK. Turbo Thomas offers a Type 3 specific header to his customers and it looks like a winner too. This header utilizes the standard type quiet pack mufflers or turbo style muffler. They will even make you a special one that fits between the rear apron and the engine for additional ground clearance.

The Type 3 header differs in that exhaust must travel farther back, as the stock Type 4 fanshroud is still in place. These systems take that into account and exit right where it should be.

The word is that Jake Raby has once again commissioned A-1 Muffler to make another system, this time a header for the Type 3 with a Type 4 engine. Whenever I get the official word from Jake, I will be sure to post the new information here along with any pictures, if available.

Thanks go to Rolf Christensen, Ron "Plastermaster" Roberts, Ephraim "Ephry73" Castillo, Rich Craig, Tom "Tom Notch" Hansen, and Jake Raby for all of their help in gathering the information and supplying photos. Thanks guys!!