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Exhaust systems are key to a performance
car. An aftermarket exhaust is usually larger in size than the stock system.
Most exhaust systems replace everything from the catalytic converter all the
way back to the tip, hence the name cat-back systems. Replacement of the stock
restrictive parts results in a free flowing exhaust and depending on the system
a louder tone than stock. There are two types of materials used in cat-back
systems, the cheaper aluminum, and more expensive stainless steel. There is no
difference in preformance characteristics in a brand new system, however over
time the aluminum systems will rust and corrode hurting performance, while the
stainless steel systems will not rust and should last at least 10 years before
replacement is required. Stainless steel is the way to go if you want the
system to last. Expect to see around 10HP with any system. However depending
on your other mods an exhaust can help out a lot. For example, if you have a
chip, filter, and a downpipe, the addition of an exhaust will maximize all the
mods you already performed. When purchasing an exhaust for a 1.8T there are
either 2.5" or 3" systems available. There is much debate as to which performs
best, but it can be assumed that when used with the stock VW 1.8T ko3 turbo the 2.5" is
great, but for any larger turbos you should use the 3" system for peak
performance. Note however that many people have used a 3" downpipe and cat
mated to a 2.5" cat-back with excellent gains. It all depends on what your plans
are and how deep your wallet is!
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