Mint Mk2 Golf Rallye with R32 V6 Conversion.
Working on these little monsters is nothing new to us, however a 4-wheel drive with lowered suspension made the job far more thought-provoking than others. Unlike like other jobs we had the pleasure to keep the Rallye on our premises overnight. This ensured that the utmost care and precision was taken to complete the fabrication to a quality finish. The correct tooling and machinery combined with ample time resulted in an unblemished end product.
The Mk2 Golf Rallye was provided with the twin down pipes supplied through a well-known brand, however small modifications were needed to clear the bulk head as well as the prop shaft. We began the exhaust system with a 2.25” Y piece merging into 2.5” pipe work. Keeping in mind that the down pipes provided for the V6 are 2”. It was crucial to try and keep the system tucked up as high as possible at the same time keeping the system clear from the prop shaft.
We were requested to try and keep the sound to a ‘head turning level’ which was accomplished through the use of our new designed bullet silencers. These bullet silencers have been designed in such a manner which as a result has two benefits; firstly, the domed down ends on the bullet silencers acts as a skid plate if you were to ever have a pickle with our good old speed bumps, secondly the internals are designed to permeate as much as possible in such a small surface area.
It was ideal to fit a secondary silencer in the middle to help keep the tone down. The remainder of the middle section was designed and completed in 2D short 45-degree bends, cut precisely on our Do-All Band 2602 Saw, finished with a stainless-steel laser cut flange set, all artistically TIG welded. The flange was a must to allow the customer to be able to take the exhaust apart to access the prop shaft. The original choice was a V Band but due to limited space a flange was sufficient at this part of the exhaust system.
As always, the rear sections on the Mk2 Golfs or the Corrados are delicate, the engineers had to work judiciously taking into account that not only do you have to squeeze between the chassis and the body but there is also the driveshaft’s. After a bit of fun, the result was outstanding. A perfectly sculpted snake created from mandrel bends and fine welding.
It is prudent that the rear silencer be an Oval silencer with a free flow internal setup, this aids in keeping the tone to an elusive character. The choice for tailpipes was a straight edged slash cut twin tailpipe. Similar to that of the euro specs, but not so abrupt. The tailpipes were polished out to guarantee that the aesthetics of the tailpipes were on point.
On start-up it was apparent that the set up complimented the Volkswagen Golf Rallye and the tone that the 3.2 V6 produced was remarkable, on idle it purred and on open throttle it roared, popped and turned heads. It is a common practise that all systems are thoroughly checked for leaks and knocking. The job was complete, and once again a positive feedback from the customer. We anticipate to hear back with the end results of the power that the dyno print shows, along with seeing the finished project on road.

	+14