Has anyone on this forum cut open a corsa sport exhaust muffler to fix a broken baffle?
I think a baffle on my driver side muffler is broken: annoying raspy buzzing sound whenever your on the gas and on the rare occasion at idle.

I thought that it was a clamp or something that I forgot to tighten when I installed my AR headers, but it isn't. I checked every nut and bolt on every flange and they are all tight.

Installed my stock Ti's and the buzzing went away. But now it's too quiet

I cannot replace them because I am not the original owner, nor do i want to buy a brand new one. Thought about taking them to a repair shop, but I have a crazy project use for these mufflers anyways and if I am going to cut them up a little bit, might as well crack open the muffler to see whats up.

 

I have a set off the car with a loose baffle as well, tempted to cut em open and see what's going on. I called Corsa to ask, a tech guy was supposed to call me back and advise but never heard anything.

 

I thought that if you were the original owner that Corsa would warranty them. It seems like I've read that.

 

ive had two claims with borla now.... not the original owner of the exhaust and they never ask.... corsa doesnt work like that?

 

Corsa systems come with a lifetime warranty IIRC. Maybe try contacting Corsa if you are the original purchaser.

 

http://forums.corvetteforum.com/c5-t...ad-rattle.html
Hope this helps. 2nd page last post..

 

OP states he is not the original owner - but still could be worth a shot with Corsa - give them a call and see what they will do.

 

The should (and one would hope) stand behind their product.

 

wow... that was fast.
okay. So at least I know I am heading in the right direction.
I'll cut the one open and post pictures of what is going on... maybe help some other people as well.

And yes, unfortunately, I am not the original owner and I'm sol if I want a replacement.

 

Good luck I know they can be fixed..

 

much appreciated.

 

Any updates to this?

 

I might cut mine open if i pull the trigger on their extreme system

 

Seems really said that you have to cut open a $1500+ exhaust system!

 

It's a slow process.
Decided to brush up on my welding and cutting for a bit... because you know... I dont want this turning into a hack job. I havent done any metal work like this for a while. I started cutting the back off the muffler (the inlet and outlet side) instead of cutting through the middle of the case because I've been told that all corsa really did is throw a small glasspack type muffler with some baffles on the inside in it's own smaller case. And the only way to access it is by cutting off the back and pulling everything out. IF that makes any sense.

So when I heard this I put one of those snake-spy cams (I dont know the actual name haha) down both sides to see whats up and as far as I can see all it is, is a big U-pipe in a big stainless steel case (The big oval thing you see). It looks like a small glasspack is on the inside close to the exit of the exhaust system.

Also ordering some different clamps (V-clamps) instead of re-using the slip joints, so I am also waiting on those. Hate slip joints. Instantly make working on exhaust a pita.
Also waiting on exhaust tubing as well so I can convert the system to just two 4.5 inch exits or something.

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While It may be sad that I have to cut open a $1500.00 exhaust... It's not like I just flushed money down the toilet. Like I said, I am not the original owner. I also don't want to buy a new system of any make. I'd rather just make my own. If it turns into a nightmare, I'll just send it to a shop to repair it.

 

Don't they have a "flap" that opens and allows the excess exhaust to escape on one of the tips? They do on the C4 Corsa and there has been much debate on whether these are actually true dual tips.

There was a member who did cut one open and it showed the flap that opened to allow the excess to escape. This is how they create the no drone. At least on the C4 systems. So the argument continued whether they were actually dual tips.

I have no knowledge on the C5 systems. But it would seem they are similar and it's possible your flap is droning

 

So this is what the inside of a Corsa Sport muffler looks like:



Getting it out was horrible, the cut looks like a hack job (which I guess it is) but thats just the metal lip that folded over during the cutting process.
Most importantly ,you can see at the bottom of the picture on the end piece that it is covered in cracks on both sides. I can almost completely remove it with my hands. It's quite fragile. This must be what is causing the buzzing sound- if you hold it up and tap the muffler with your hand it makes the same buzzing sound. The big pipe on the left is just a glasspack of some sort.


IF my repair job doesn't work, I'm just going to get some mufflers made similar to the Kooks mufflers (http://forums.corvetteforum.com/c6-p...fflers-fs.html). I've measured and they would fit, instead of going under the rear bumper, just straight out under the car out the back.

 

I know this is an old thread but I was wondering if you can give some more info about how you opened up the exhaust. Did you just cut all the way around the inlet/outlet side and then the case slides off? Or did you have to cut open both sides? I also sent you a PM because I'm not sure if you will see this.

I'm in the same situation that you were as I am not the original purchaser of a corsa exhaust and I have a rattle in the driver's side muffler. Since it is an expensive paper weight right now, I figured I might as well chop it up and try to fix it.

 

My exhaust guy told me he cut open a Corsa muffler for a C5 and was able to repair a buzzing noise. There was also a single side Corsa Pace muffler on the auction site but don't remember which side.

 

I answered my own question. If you cut around the inlet/outlet side the case slides right off. My pipe connecting to the inlet side had the welds let go. I welded it back together but I will need to take it in to finish. The case is fairly thin and I'm not able to weld it with my skills/tools without burning through it. Here are some pictures for anyone interested. Not sure the exact model of mine but it is one of the early designs for a C5.