Exhaust Install Question

[TheBlackPearl]

Does anyone know when removing the factory exhaust do you unscrew the 3 bolts on the passenger side headpipe flange or just the clamp. In the Corsa instructions it says just remove the clamp, but that the 90 also has a headpipe flange which other years don't. It doesn't say anything about unscrewing the three bolts. I've done everything else and I'm trying to pull the exhaust off and it won't budge.

https://imagizer.imageshack.us/v2/1117x629q90/r/404/rztk.jpg

[Franke]

My 90 didn't have a head pipe flange on the passenger side. Just a clamp. I put on a Corsa system and used the new band clamp to reinstall that came with the kit. I think you need to remove the bolts based on what I see. You may have to modify your new Corsa pipe for a flanged connection..

[TheBlackPearl]

Well I took the bolts off along with the exhaust. Problem is the flange is in the way and won't come off so now I need to cut it off because it won't hammer off. Any other ideas to get it off without cutting?

[TheBlackPearl]

https://imagizer.imageshack.us/v2/992x558q90/r/89/8fzt.jpg

[Franke]

Yes. Does that flange look like it has a slip fit pipe behind it or is it welded in place? If slip fit then split the pipe from the slip side lengthwise with a cold chisel or air chisel and peel it off. If welded, the pipe will have to be cut or leave it in place and modify the new pipe to fit with a flange.

[TheBlackPearl]

It's a slip fit. Damn thing just won't budge though. I'll either take a chisel to it or get out the saw.

[Franke]

You could possibly use a 4 inch cut off wheel and split the pipe. Just don't go too deep. When the tension relaxes it will come off.

[TheBlackPearl]

Just what I was thinking. Thanks Franke for helping me out.

[mike100]

I ran into a similar problem which I solved by welding the mating half of a 3" triangular flange to my aftermarket pipes. I limped it to my exhaust guy because he's only 1 mile down the road. and yes, it was really loud.

[TheBlackPearl]

I think I want to start it up while the exhaust is off, maybe scare a couple kids in the neighborhood. :D Corsa wants the slip pipe to be taken off, and cutting it off will be the easiest way to get the system on the car.

[TheBlackPearl]

Is the center muffler supposed to be touching the diff?

https://imagizer.imageshack.us/v2/1117x629q90/r/703/pww4.jpg

[WARP TEN]

Is the center muffler supposed to be touching the diff?

https://imagizer.imageshack.us/v2/1117x629q90/r/703/pww4.jpg

This is a common problem. For me it has always been the driver side pipe hitting. Marc H says just get a breaker bar or a large strong screwdriver and place it between the pipe and the diff and lever it down. He said it takes a lot of force but will get the pipe to bend. I did this but also took a small square of silicone hose material (about 2" x 2") and put it between the pipe and the diff, held in place with some hose clamps. Seems to work fine. Did it on both my old Corsa and on the stock system with cutouts. --Bob

[Franke]

What Warp Ten said. I had the same issue and just adjusted it with a large tool too. :) Looks good. How did the old flange come off?

[TheBlackPearl]

Yep, driver side. I got the flange off with the cut off saw. I'll post pics later.

[TheBlackPearl]

The exhaust is louder than I thought it would be at idle, which is great. But it isn't as loud as I thought it would be at WOT. Maybe it's because i'm in the car and not behind it to hear just how loud it is. Overall i'm very happy and it's leaps and bounds better than stock and well worth the money. I would say that when I buy a C5 Z06 some day i'll probably go with the Corsa Xtremes, but i'll see how I feel after living with the Sports for some time.

https://imagizer.imageshack.us/v2/1118x629q90/r/856/w0tce.jpg

[scottfab]

There is no need to bend anything at all.
Just loosen up all the fasteners, place a 2x4 between the diff and the pipes then tighten back up. Lastly when you're fine on the pipe to diff clearance, set the muffles straight and tighten fasteners then set the tail pipes where you want them.

Is the center muffler supposed to be touching the diff?

https://imagizer.imageshack.us/v2/1117x629q90/r/703/pww4.jpg

[Schrade]

This is a common problem. For me it has always been the driver side pipe hitting. Marc H says just get a breaker bar or a large strong screwdriver and place it between the pipe and the diff and lever it down. He said it takes a lot of force but will get the pipe to bend. I did this but also took a small square of silicone hose material (about 2" x 2") and put it between the pipe and the diff, held in place with some hose clamps. Seems to work fine. Did it on both my old Corsa and on the stock system with cutouts. --Bob

That would have been by first thought too - some sort of bushing, secured into place.

Absorbing vibration - acoustic, mechanical, etc., goes a LONG way. Even if only in the exhaust lines.

Take a ride on Germans' HSR train. Those rubber-inset wheels make you think you're puttin' along @ 70, when the whole train is zippin' along @ 190 !!! :eek:

Go rubber, or vulcanized Silicone bushing.

[TheBlackPearl]

So what do you guys think?

https://www.youtube.com/watch?v=9DhaKRlYTOM

[Franke]

I like it.

[Z06scentair]

I like it.....sounds like a mean 4cam motor.


If I want old school muscle, I would climb in the 65 L78 or the 69 Z28 and row through the gears.