front stabilizer bar/exhaust clearance

[Larry" <rocco16v@netzero.com (Larry)]

Do not weld, it should be a high-carbon steel, which will get very
hard/brittle if you weld.  For the same reason, do not heat to bend it.
Bend it cold.  We had to do this on son's MkI, for the same reason (exhaust
interference) and it has not given any problems in two years.

Larry  sandiego16v

>
> While I'm waiting for a local supplier to provide me with a 2.25" madrel
> bent 90 degree elbow so I can upgrade the downpipe on the TD Roc, I'm
> pondering how I can resolve clearance issues that will be a concern with
> the larger diameter pipe as it crosses over the stabilizer bar.
>
> When I took a boo at the pictures of the Mk2 Twins that Tobias posted, I
> saw the underside shot which clearly indicates a significant u-bend in the
> front stabilizer to accomodate the downpipe.
>
> Now it seems to me that the front stabilizer may have come with factory
> with a slight bend in it, or it may just be that the A1 cars I've had (2
> GLIs and a couple of Sciroccos) have all had the bar bent to solve exhaust
> clearance issues...  Doubtful.
>
> I'm not sure I'd be able to achieve the necessary clearance by heating and
> bending the bar further, as the length is likely not there.  I'm guessing
> I'm going to have to drop the bar another inch to avoid having to "dent"
> the downpipe (which I can do if necessary, but would rather not)
>
> The other thought I had was to cut the centre out of the bar and weld
> another section of bar (with a U bend in it already) to the underside (or
> the backside, depending on how pronounced the U is...) to provide the
> necessary clearance.
>
> What are people's opinions on welding to the stock bar?  I would likely
> use a chunk of stock A2 bar (from a Jetta GL, not a GLI, so the diameter
> would be closer to the A1 bar's) so's not to trash a perfectly good A1
> bar.  Does anyone have any insight into the composition of the bar?  I've
> never tried cutting/bending it - I'm assuming it's not mild steel, but I'd
> hope it's not super-hardened either.
>
> Thoughts?
>
> Drew MacPherson - '84 Wolfsburg Edition Scirocco TurboDiesel
>
>
>
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