Weld broke on exhaust 3rd time..
Thread Starter
Instructor
Joined: Apr 2004
Posts: 110
Likes: 0
From: New York
Weld broke on exhaust 3rd time..
I have a 98 Coupe. A few years ago, the weld on the stock X pipe broke at the rear tail pipe/mufflet flange. I had it welded and seems to be fine now. Two years ago, my wife was driving away from home when the r/rear flange weld broke on the tail pipe allowing the pipe to contact the rubber axle boot damageing it. AShe got it to a muffler shop and they were able to weld it and also welded the left side as insurance but told her tey would break again down the road. Last week on her way to work the left side tail pipe broke at the flange to the X pipe - WTF? I have heard that this is a problem with some C5's. Is this true. Now I have to get it to a friends garage to get it up in the air to remove the tail pipe. Anyone know a cure for this on the stock exhaust? If anyone has a good set of stock C5 tail pipe/mufflers that they have removed for a performance exhaust I would be interested in them. If anyone has a take off set PM me. We have a lot of home improvements going on right now so a performance exhaust is out and beside, the stock one works for us. If I can find a set, I have a friend who is a good welder. I thought about having him weld a set if I can find them. Any thoughts? I really am kind of disgusted at this point.
Sorry for the long post,
Klammer
Sorry for the long post,
Klammer
Instructor
Joined: Jun 2008
Posts: 155
Likes: 20
From: Reno NV
I would not think the welds would break if they were done right. How are the other hangers along the system, and maybe check your motor mounts just to make sure you are not getting any stress on the system.
Safety Car
Joined: Feb 1999
Posts: 4,044
Likes: 342
From: Central NJ
This is a very common problem on the early C5s. I have a 99 and replaced the stock H pipe with an aftermarket X-PIPE. The welds on my stock pipe were horrible. I am sure it would have broken as well. You should get an aftermarket X-pipe and be done with it....
Advanced
Joined: Oct 2005
Posts: 92
Likes: 1
From: CT
This is in fact a common problem & the issue is with the OEM welding itself. The OEM part is just stick welded. Mine broke on both sides completely pulling the weld out of the flange. The weld remains stuck to the pipe.
It can be repaired but there is significant labor. I welded mine on the opposite side of the flange. This requires that you grind a nice bevel on the back-side of the flange. The old weld actually makes a good locating key to get the flange back where it belongs. TIG weld with a rod appropriate for Stainless & then grind the weld flat (since it's now on the mating side of the flange).
It can be repaired but there is significant labor. I welded mine on the opposite side of the flange. This requires that you grind a nice bevel on the back-side of the flange. The old weld actually makes a good locating key to get the flange back where it belongs. TIG weld with a rod appropriate for Stainless & then grind the weld flat (since it's now on the mating side of the flange).
Thread Starter
Instructor
Joined: Apr 2004
Posts: 110
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From: New York
Thank you for the replies. I had heard that the welds were a problem on early C5's. Does anyone know when or what year the weld problem was corrected (ie what years shold I avoid for stock mufflers)? I am now thinking about installing an aftermarket X pipe (cat back) to a set of stock mufflers that I can get from some other members here. I hope that solves my problem. Another question I have is there any advantage to Zo6 mufflers vs stock C5 in a car like mine that is completely stock?
Thank you for the help,
Klammer
Thank you for the help,
Klammer
Tech Contributor
Joined: Jan 2007
Posts: 19,493
Likes: 1,178
From: Dyer, IN
Safety Car
Joined: Feb 1999
Posts: 4,044
Likes: 342
From: Central NJ
If you go to Corvettes of Carlisle you can get a stock exhaust for free as the muffler vendors replace them there if you buy a set. Most folks just leave the old systems there for the trash... I got a set of stock mufflers out of the garbage pile....Just an FYI
Thank you for the replies. I had heard that the welds were a problem on early C5's. Does anyone know when or what year the weld problem was corrected (ie what years shold I avoid for stock mufflers)? I am now thinking about installing an aftermarket X pipe (cat back) to a set of stock mufflers that I can get from some other members here. I hope that solves my problem. Another question I have is there any advantage to Zo6 mufflers vs stock C5 in a car like mine that is completely stock?
Thank you for the help,
Klammer
Thank you for the help,
Klammer
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Team Owner
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From: Dear Karma, I have a list of people you missed.
St. Jude Donor '08-'09-'10-'11-'12-'13-'14-'15-'16
If your concerned, you can also just have any replacements re-welded or reinforced before installing them. Cheap and easy to do.
Thread Starter
Instructor
Joined: Apr 2004
Posts: 110
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From: New York
Team Owner
Joined: May 2001
Posts: 36,836
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From: Dear Karma, I have a list of people you missed.
St. Jude Donor '08-'09-'10-'11-'12-'13-'14-'15-'16
just get the bandbs
