Flywheel and exhaust queries

I'm installing a 4T gearbox into my '76 golf 1.6. Gearbox is off a Jetta '89 mod with 210 mm clutch originally. Seeing as I might upgrade to a 1.8 engine in the future, are there any reasons why I should't just mount it with a 210 mm flywheel/clutch on my 1.6 non-gti Golf? Or would it be bad in terms of final drive and stuff like that?

Secondly, I'm upping the steering with anti-roll bars front and rear. Problem is the front ARB will hit the down pipe as mine doesn't have the bend to accommodate it. So my options are either to buy a used 6-bolt gti manifold + downpipe, or level up with a 4-2-1 manifold. Is there any reason why I shouldn't fit something like i the photo? Seems legit to me..?

Hope anyone has the time to give an opinion on this, hopefully it'll help others as well

I have a 4–2 g60 manifold with a dual down as I had a catalytic Pervertor on my cars until they hit 25yrs old.

I have a SS Raceland header like the one pictured hanging about waiting for the head work if I ever need to do it… It will go on as it is a CAT delete thing….and since I killed the cat…. You will need to add a flexure piece to it.
Sorry for the wrong picture dang nab pbucket.

 

I have fitted a 4 2 1 manifold to my Gti and you can tell the difference in driving the car compared to the toilet bowl down pipe I had before, it's freed up the top end of the rev range.

My 4 2 1 is fitted to my standard exhaust system via the adapter you may need a different adapter as I belive the standard 1.6 exhaust is smaller diameter compared to the 1.8, it is on my 78 1.6 mk1 Scirocco compared to the 88 1.8 Gti golf.

The manifold runs close to the UJ rubber boot so you will need to alteast wrap the boot or like me the boot and exhaust manifold as well so the gasses escape quicker and to protect the boot.

It is a bit tricky fitted the manifold and don't install the anti roll bar till after the manifold is fitted as you need to remove it to fit.

The 4 2 1 system took a few attempts of moving the standard exhaust system around and twisting etc to stop it banging on the floor or rear beam or heat shield on the gearstick but I got there in the end.


I'm a little surprised your 76 golf does not have the 6 bolt manifold, my 78 Scirocco has one fitted from new so I could just fit a Gti down pipe to go over a front anti roll bar if I fitted one as like you I don't have a anti roll bar.

Thanks for the tips guys, always to the rescue!
yes I do have the 6-bolt manifold, but the non-gti version, which has a smaller mounting surface and will not fit the gti-downpipe with the ARB-bend. I know it's smaller because I had it off this winter, and the 6-bolt gti seal I bought was to big to fit.

Anyway then I'll settle with the 4-2-1. I'm gonna have to do the rest of the exhaust as well, since the corrugated pipe won't match the new 4-2-1. Also the previous owner replaced the exhaust sometime in the 80's if he recalled so it's about time :p

I'm not really into the sport exhaust look/sound, so will probably fit the gti version middle and rear silencer, or is that a bad idea on a 1.6 non gti? And Briano, do i need the flexpipe even though the 4-2-1 has a bend for the ARB?

About the flywheel, would a 210 mm fit the 1.6? Don't want to spend serious krone on a 190 mm clutch if I'm fitting a 1.8 engine in a year or two..

Current downpipe. Pardon the disgustingly filthy engine bay.

Is your car a left hand drive?

I did not realise there was a difference in the 6 bolt manifolds, I thought they was all the same with the big block engines, something I’ve learnt today.

Yes, I learnt it by the classical "I ordered the wrong part-way".. it's a Norwegian left hand drive.

With the g60-4-1-2 manifold and dual down pipe, the down pipe contains the flexure. that allows the engine torque to not damage the pipes.

For heat shielding I made a wrap of sheet aluminum and bolted it to the down pipe.


Works well.

G60 4-2 manifold and dual down off a mk2 golf. I had my exhaust guys make me a dual down with the old parts.




Next to it is a old rocco, solid dual down…