Bobcat Exhaust, 1-5/8 with U-Bend Muffler, Stainless

OVERVIEW

When you''re building a high-performance air-cooled engine, the exhaust system is often the bottleneck that prevents you from reaching your true horsepower potential. The EMPI Bobcat Exhaust system, crafted from premium stainless steel, is engineered specifically to solve this problem for high-displacement Type 1 engines. Featuring massive 1-5/8 inch primary tubing, this system provides the necessary volume to allow 2000cc and larger stroker engines to breathe freely. Unlike restrictive stock-style mufflers or small-diameter street headers, the Bobcat system utilizes a merged-collector philosophy that optimizes exhaust scavenging, pulling spent gases out of the combustion chamber more efficiently to improve throttle response and top-end power. The stainless steel construction isn''t just about aesthetics; it''s about longevity. This system is designed to withstand the extreme heat cycles of a performance flat-four while resisting the corrosion and "rot" that typically plagues mild steel exhausts in humid or coastal environments.

The standout feature of this specific model is the integrated U-bend stinger coupled with a high-flow stainless steel racing muffler. This configuration is the "holy grail" for Volkswagen enthusiasts who want an aggressive, high-performance look without the ear-splitting decibel levels of an open stinger. The U-bend design effectively lengthens the exhaust path, allowing the included racing muffler to mellow out the harsh "crack" of the engine note into a deep, authoritative rumble that is much more suitable for street cruising or long-distance drives in a Dune Buggy or Baja Bug. To ensure a leak-free sealwhich is critical for maintaining consistent backpressure and preventing popping on decelerationEMPI has equipped this system with extra-thick, precision-ground flanges. Whether you are tearing up the dunes or showing off at a local meet, this Bobcat system delivers the perfect balance of show-quality finish and race-ready performance that Appletree Auto customers demand.

FITMENT

• Volkswagen Type 1 Beetle: 1950-1979 (Requires rear apron clearance or removal)
• Volkswagen Karmann Ghia: 1956-1974 (Body modifications likely required for clearance)
• Volkswagen Type 181 Thing: 1973-1975
• Dune Buggies: All Years (Manx, Meyers, Berrien, and Rail styles)
• Baja Bugs: All Years (Ideal for high-clearance off-road builds)
• Engine Compatibility: Optimized for 2000cc, 2110cc, 2275cc, and 2332cc Type 1 upright engines

SPECS

• Material: High-Grade 304 Stainless Steel for maximum corrosion resistance.
• Primary Tubing Diameter: 1-5/8 Inch (41mm) Heavy Duty Mandrel Bent Tubing.
• Exhaust Configuration: 4-into-1 Merged Collector for superior scavenging.
• Muffler Style: Stainless Steel High-Flow Racing Muffler with U-Bend Stinger.
• Flange Thickness: Extra-thick heavy-duty flanges to prevent warping and exhaust leaks.
• Finish: Fully Polished Mirror Finish for show-quality appearance.
• Hardware: Includes necessary gaskets and mounting hardware for standard installation.
• Weight: Approximately 21.35 lbs.

PRO TIPS

Tip 1: Proper Heat Cycling and Tightening

Stainless steel has a different rate of thermal expansion compared to traditional mild steel or the aluminum of your cylinder heads. When you first install your EMPI Bobcat system, don''t just bolt it on and go for a high-speed run. We recommend a "heat cycle" process: start the engine and let it reach operating temperature, then shut it down and let it cool completely. Once cool, go back and re-torque all the exhaust nuts at the heads and the collector. You''ll likely find that the expansion and contraction have slightly loosened the hardware. Performing this twice before your first major outing will significantly reduce the risk of blowing out an exhaust gasket or developing a persistent leak that can lead to burnt valves.

Tip 2: Clearance and Body Protection

The 1-5/8 inch Bobcat system is a "large-footprint" exhaust. If you are installing this on a standard Beetle or a Karmann Ghia, you must be prepared for fitment challenges regarding the rear apron. Because this system is designed for maximum flow, it sits differently than a stock pea-shooter. We highly recommend using a set of "stand-offs" for your decklid or trimming the rear apron to prevent the heat from the stainless tubing from bubbling your paint. For Dune Buggy owners, ensure your cage or bodywork has at least 2 inches of clearance from the U-bend to allow for engine torque movement; otherwise, you may experience annoying vibrations or structural cracking over time.

Tip 3: Tuning for the Increased Flow

Upgrading to a 1-5/8 inch merged system from a smaller 1-3/8 or 1-1/2 inch header will drastically change your engine''s air-fuel requirements. Because this exhaust pulls air through the engine much faster, your existing carburetor jetting may suddenly become "lean," especially in the mid-to-high RPM range. After installation, Appletree Auto specialists recommend performing a spark plug reading or using a wideband O2 sensor to check your mixtures. You will likely need to increase your main jet size by one or two increments to compensate for the improved volumetric efficiency. Running too lean with a high-performance exhaust can