Hey all you Dieseler's out there, I was reading on TDIClub.com about doing what they call a "mufflerectomy," and it sounded easy and cheap, so I went for it yesterday.
Basically, you just cut out the muffler and replace it with straight-pipe.
Let me tell you, it was easy to do, with the proper tools... Floor jack, decent saw to cut the muffler with, and a welder.
After starting the car without a muffler...
WOW! It was AWESOME! It sounds SO SO cool now, and cost me $20 bucks in parts, and took about an hour to do.
The throttle response is a lot quicker now, although I'm not sure on how many horsies I've gained, but did notice a difference, especially at high-speeds. Jumps from 80 to 90 in no time now, whereas before it kinda started lagging after 3300 rpms or so.
I put a tip out the back and noticed a little more smoke, but nothing unacceptable, and only when I'm punching it.
But most of all, the SOUND.
It SOUNDS so cool. If nothing else, do this mod for the sound. It's not noisy or rattly-bang like, (*cough* Honda *cough*) It actually sounds like a VR6 or something now. Just a nice low growl, doesn't even sound like a Diesel anymore from the back. Turbo spool is easily heard, along with the turbo whistle. I think the cabin-noise has actually DEcreased, although I've heard mixed feelings about it on tdiclub.com
I recommend it to ANYONE with a TDI.
I also recommend not doing it before any type of formal get-together, i.e. weddings, funerals, work, etc. as you tend to keep your window down more to hear your new exhaust, in turn, losing your lovely hair-do.