A potential delete option for the DPF

[Seano]

Hey there....in hunting around for a new Cat converter for my T4 (VW wanted $1500 exchange fitted - I got one for $240 fitted) I came across an Australian company called www.microfreshfilters.com.au.

They have a diesel catalytic converter that not only removes the typical gaseous exhaust components but also functions as a DPF. They were originally developed for diesel engines and vehicles used in underground mines or confined spaces and as such must have extremely good exhaust quality both for air quality but also low flammability - the company also sell replaceable exhaust gas filters that fit on the end of the tail pipe of these engines to polish the air.

Anyway....these catalytic converters are available in sizes to suit our Volkswagens. They aren't cheap but if you want get the most out of your engine, don't want the OEM DPF mucking that up but are worried about the EPA and the black smoke...then this product might well be an option.

I asked for info about the 50mm model suited to the 2.5L TDi which I selected based on info at their website. But they have much bigger models as well - for those with 3" exhausts

Here's an edit of the email I got back from them...on the same day

Hi Sean,

We do not have agents in your territory for this technology as yet.

You can however order direct from us.

Cost of IC-5-200 would be $1506 + GST.

Point to note however is that this is a particulate catalyst technology designed for removing Diesel Particulate Matter (DPM) as well as the major gaseous pollutants (CO + HC). Your OEM spec unit is probably only targeting gaseous pollutants and doing nothing to minimise particulate emissions (the black smoke). We more commonly utilise this technology in underground mining and enclosed space applications where diesel emissions represent a significant health and contamination risk. Having said this we are seeing increased interest from on-road sector where environmental concerns are the predominant factor.

Please do not hesitate to contact me should you wish to discuss further.

Kindest Regards,

Steve


Stephen Gledhill (BE Mech)
Manager - Mining
Micro Fresh Filters Pty Ltd
69 Malcolm Road
Braeside, Vic, Aus, 3195
P: +61 3 9587 9488
F: +61 3 9587 9400
M: +61 (0) 419 347 769
E: steve@microfreshfilters.com
W: www.microfreshfilters.com

[gldgti]

Thats some good info - a little on the pricey side, however, next to a VW DPF replacement cost it will definately be the cheaper option - by a long way.

if they did one in 2.5" it would be perfect, but no reson you cant weld in a couple of 2.5 - 3" reducers either end of a 3" unit.

[Seano]

In the models to suit engines with displacements from 2.0 to 4.0 litres, they do four versions in the following sizes: 2", 2.25", 2.5" and 3"

So you could have what you want.....if of course you are prepared to pay. Although I suspect that they are all around that $1500 plus GST mark.

You also need to bear in mind that these units are made of stainless steel. So they can't simply be welded into place in a normal mild steel exhaust system.

[Greg Roles]

Nice find. It's intresting there are a lot of these alternate options out there, I've discovered a few along the way, and it seems come DPF replacement time, once your car is out of warranty, there's a lot of cheaper options. You can wld stinless to mils steel, it's just that it's not ideal, and the weld's would be messy and rust. Still if it saves you a few thou over an OEM VW DPF, I could live with it.

And Ayden mate, you WANT an oversize DPF, as it's such a major restriction, I'd be trying to fit a 5" one from a small truck!! It's why I'm putting a 3" muff in a 2.75 / 2.5" system, as it's the point of restriction. Bigger is indeed better for flow ( up to a point ).

[sparkie]

Would it not be relatively easy to expand the mild steel slightly so it slips over the Stainless and then use an exhaust U bolt to clamp it all up, that way you could also remove the filter and transfer it if you change vehicles.

[gldgti]

Nice find. It's intresting there are a lot of these alternate options out there, I've discovered a few along the way, and it seems come DPF replacement time, once your car is out of warranty, there's a lot of cheaper options. You can wld stinless to mils steel, it's just that it's not ideal, and the weld's would be messy and rust. Still if it saves you a few thou over an OEM VW DPF, I could live with it.

And Ayden mate, you WANT an oversize DPF, as it's such a major restriction, I'd be trying to fit a 5" one from a small truck!! It's why I'm putting a 3" muff in a 2.75 / 2.5" system, as it's the point of restriction. Bigger is indeed better for flow ( up to a point ).

sure, thats why i mentioned it could be easily done

btw - theres no probs welding stainless to mild steel. no galvanic reaction occurs, theres no reason for the ms to rust any faster.... trust me, i do it every day in a professional sense

(also, no reason for the welds to look any worse - bad welding is the operator

[gldgti]

You also need to bear in mind that these units are made of stainless steel. So they can't simply be welded into place in a normal mild steel exhaust system.

as above, just to clarify, you can, its no problem. different welding methods produce differing results, but in any case its A-OK.