Replacement exhaust

1) If the backbox is solid enough to bolt back on then it'll be fine. When it's ready for replacing it will automatically corrode and eject itself from the car. I still have no idea when or where mine fell off!

2) Cleaning the inside of your exhaust could be classed as OCD

3) Stainless will last forever unless you snap it but as you say it could still get caught/damaged when off road.

4&5) "straight through" is just replacing the silencers with straight pipes, either the middle box or the back box, NOT both or you'll go deaf instantly!! It will help the engine breathe especially when the EGR is blanked and a de-cat downpipe is fitted but the word 'performance' could be a bit strong.

I replaced my whole system last year, de-cat downpipe, straight through pipe to replace the middle box and a new back box. Sounded a bit throatier (better) but not too loud but I didn't really feel any performance increase. Overall really pleased and would recommend it.

But, if I do it again I'll put a middle box back in and replace the back box with a straight through side exit pipe as it keeps digging in when I'm laning. Others on here have done the same and the noise levels are supposed to be similar.

Thanks very much for that. Thats really useful information!

So i think i will go for mild steel either way. Follow up questions are

1) what difference does it make going straight through the first or second box? does one remove more noise than the other?

2) what is EGR?

3) I had a check and my 200tdi doesnt have a cat.... if this is factory standard, is it still classed as 'de-cat'?

I never thought about going out the side. I guess that just gives an extra couple inches at the back? I will have a look at the rear profile of the car and see if its of use for me.

Both boxes are about the same size so the results would be similar. Hopefully someone with experience of both setups can answer more accurately.

There are dozens of threads about removing/deleting the EGR valve. All you need to know is that if yours is still fitted then it's your next job

Not sure about the 200tdi but my 300tdi had a flexi section and a cat/dpf box in the downpipe between the manifold and the middle box. This was replaced with a single solid pipe (defender item as it was cheaper than the disco with the flexi section).

Once I removed my tow bar and fitted a tank guard the back box seemed to stick out like a sore thumb.

200tdi has no cat or egr unless it's an export model.
Mine has no silencers and a short down swept pipe off the downpipe, it's not quiet but is bearable inside the car, mine has no sound deadening or carpets either, admittedly the tyres tend to drown out the exhaust though.

So, i have found my options, but i am not too sure what one to get. I have listed them belwo but i suspect i may just need to call the shops....or maybe you guys know!

This one says 'full system' but it only shows one silencer. am i missing somethign?
Full System - Mild Steel - 200Tdi - Aftermarket at www.rimmerbros.co.uk

This one says centre and rear assembly, but shows more than the first one!
Centre & Rear Assembly - Mild Steel - 200Tdi - Aftermarket at www.rimmerbros.co.uk

Paddock shows centre and rear, i assume its the same as one of the ones above
ESR238 | Centre and Rear Silencer Assembly - 200TDI Non Cat

I assume this next one is just the end box and tail pipe...but would it have the pipe from the front box to the rear?
Discovery 1 TDi 200 Complete 1 x Middle Box 1 x Tail Pipe

Or of course i go for the 'straight throuh' for the second box and get this one. But the end doesnt look too 'tail pipe like'. So would i need other bits to finish it off?
NEW PRICE Silencer replacement pipes STAINLESS STEEL - Discovery - Defender

From the little I know the exhaust system on a 200tdi came with two silencers and a cat, apart from the very early ones (and ones from Japan?)
However the favourite mod of most in this parish is to dump the cat and the middle silencer.I think this is what is ment by straight through, I did it on my 300tdi, making the exhaust a lot cheaper and slightly louder, you're supposed to get more power too.
Get yourself a parts manual once you've found the part it gives you all the change points for the many upgrades!