Corsa Muffler Rattle
Thread Starter
2nd Gear
Joined: Aug 2025
Posts: 2
Likes: 0
Corsa Muffler Rattle
Hi all,
I have the Corsa Sports on my C6 and the driver's side has developed a pretty bad rattle sound - video attached. The rattle can even be heard with the car off when you tap around the muffler and shake it. It seems like pressing on the muffler from the bottom or back/front help alleviate the noise...which makes me think some of the internals might be broken. The noise happens at idle, revving and driving. Unfortunately, it's not covered under warranty since it was purchased from a private party. I had a shop check clearances and clamps while it was in getting other work done and it doesn't appear to be coming in contact with anything else.
Has anyone experienced such a thing? What was the fix and were you successful cutting open the muffler?
I have the Corsa Sports on my C6 and the driver's side has developed a pretty bad rattle sound - video attached. The rattle can even be heard with the car off when you tap around the muffler and shake it. It seems like pressing on the muffler from the bottom or back/front help alleviate the noise...which makes me think some of the internals might be broken. The noise happens at idle, revving and driving. Unfortunately, it's not covered under warranty since it was purchased from a private party. I had a shop check clearances and clamps while it was in getting other work done and it doesn't appear to be coming in contact with anything else.
Has anyone experienced such a thing? What was the fix and were you successful cutting open the muffler?
Last edited by C6ytime; Aug 18, 2025 at 08:58 PM.
Melting Slicks
Joined: Jun 2014
Posts: 2,236
Likes: 498
From: NJ
Look for the spot welds on the muffler case, chances are one or more let loose. Without cutting the case, put a self-drilling, sheet metal screw (SMS) thru near the spot weld, not on the spot weld itself as the metal is too hard in that area. Drill a hole first, the size of the major diameter (peak of the threads) of the SMS and then let the self drilling SMS grab the inside metal piece that is loose. If they are stainless steel mufflers, you will have to drill, with a VG drill bit, both pieces of metal with the inner piece drilled for the minor diameter (root of the threads) of the SMS. Stainless is too hard to drill with a self drilling SMS and will just push the inner piece out of the way. This is why I recommend using a good drill bit as opposed to a self drilling SMS. This is only if S.S. mufflers. Actually Stainless Steel is not hard, it just work hardens as you drill it.
Melting Slicks
Joined: Oct 2022
Posts: 3,340
Likes: 1,934
From: Ulta Vista, AZ
The baffles probably broke off. Mine did the same thing.
If you pull off the muffler, look inside the back for broken baffle chunks.
If you bought them new, Corsa will warrant them supposedly. If you aren’t the original owner, they will tell you to kick rocks and won’t support their product with lifetime garuntee.
If you pull off the muffler, look inside the back for broken baffle chunks.
If you bought them new, Corsa will warrant them supposedly. If you aren’t the original owner, they will tell you to kick rocks and won’t support their product with lifetime garuntee.
Thread Starter
2nd Gear
Joined: Aug 2025
Posts: 2
Likes: 0
Look for the spot welds on the muffler case, chances are one or more let loose. Without cutting the case, put a self-drilling, sheet metal screw (SMS) thru near the spot weld, not on the spot weld itself as the metal is too hard in that area. Drill a hole first, the size of the major diameter (peak of the threads) of the SMS and then let the self drilling SMS grab the inside metal piece that is loose. If they are stainless steel mufflers, you will have to drill, with a VG drill bit, both pieces of metal with the inner piece drilled for the minor diameter (root of the threads) of the SMS. Stainless is too hard to drill with a self drilling SMS and will just push the inner piece out of the way. This is why I recommend using a good drill bit as opposed to a self drilling SMS. This is only if S.S. mufflers. Actually Stainless Steel is not hard, it just work hardens as you drill it.
The baffles probably broke off. Mine did the same thing.
If you pull off the muffler, look inside the back for broken baffle chunks.
If you bought them new, Corsa will warrant them supposedly. If you aren’t the original owner, they will tell you to kick rocks and won’t support their product with lifetime garuntee.
If you pull off the muffler, look inside the back for broken baffle chunks.
If you bought them new, Corsa will warrant them supposedly. If you aren’t the original owner, they will tell you to kick rocks and won’t support their product with lifetime garuntee.
Melting Slicks
Joined: Oct 2022
Posts: 3,340
Likes: 1,934
From: Ulta Vista, AZ
Corsa is not even close to the quality people try and make them to be. If they can’t even fully weld tips on, and have protruding ugly
tailpipes inside the tips, I can’t see why people pay $2500 for these things
