Found multiple holes in my muffler

[Mgt2]

Please point me to the right direction!
I noticed that the tone of the Corsa cat-back in my pp2 has drastically changed to a somewhat flat tone. Came to fine out that there are 2 holes in the muffler around the areas show in the attached picture. Keep in mind that the muffler is till under warranty. I have not submitted a warranty request yet. Based on you guys experience, will I have any issues with Corsa due to road debris that might have caused it? I have no recollection that I ran over nothing that might have caused it.

Thank you so much!

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[17MagMetal]

It looks like corrosion weakened it and the road killed it. Unusual, as the fancy grade stainless used in high end exhausts shouldn’t disintegrate that quickly…

Is that THE low spot? You might have an argument for a warranty if condensation weakened your pipes enough to cause this.

 

[Mgt2]

Yes, it is at the low spot areas. Where I park in the garage always has condensed water on the floor and I drive with my windows down 99% of time, that couldn’t be AC water the 1% is when the wife is in the car.
will submit a warranty request and keep my fingers crossed.
this is my 3rd Corsa, never had an issue with their products till now.
Thank you so much for your advice.

 

[Johnny Rockit]

It looks like welded material broke loose. Too clean to have been debris as there is no dent or scratches. File a warranty claim.
-Just my opinion.

 

[Mgt2]

Thank you for the feedback. I’ll file a warranty claim asap.

 

[Skye]

It looks like welded material broke loose.

OP,

I don't want to interfere in repairing your ride. And I do hope everything works out.

Car is garage-kept. I considered theft, but usually they just go in with huge cutters and lop things off.

By chance, was there an attempt to install cutouts in the past? One of the photos, it looks more like cutting by torch, welding, heat, slag, etc.

Did you install the system yourself? If not, any chance the installer mis-understood your instructions and began installing cutouts?

IDK. Maybe something happened at the factory, they repaired and then shipped. The manufacturing lines and marks on the piping are aligned.

Just curious.

Edit,

I'd have to go back re-learn and confirm, but if something happened, a repair was made, and the repair involved two different metals which were later grounded, they'd corrode over time.

 

[IPOGT]

Throw some muffler wrap on it and or some S/S exhaust clamps.

 

[RazzaRossa]

Looks like a circular patch that failed, you can see what looks like a weld. Weird its on both sides. Edit: After looking again, the die lines are continuous, that would be hard to duplicate with a patch.

 

[Mgt2]

I installed it myself with my buddy!
That wasn’t my first time installing Corsa cat-back in my gt. Never had issues with their system prior to this one. None one drives my car.

You mentioned cutouts/by torch, my car has never slept outside not did the car has been somewhere where it had to spend the night outside. In the case of going somewhere and stay overnight, thank God that I have a different vehicle just for that.

As I mentioned in my post, there’s condensed water coming from the muffler on the spot where the car parks after each drive. 99% of time don’t use a.c just to enjoy the harmonious sound of the muffler.

 

[RazzaRossa]

If the Mfr. doesn't honor a claim, patch it an drive it till it rots of completely, then replace it at that time.
Cars have been spewing water from the exhaust since the catalytic converter was introduced, and could rot thru where it sets after not running for however long it sits.

 

[MAGS1]

Doesn’t Corsa have a brace that is welded on at that particular spot (that’s the XX pipe, right?)? It looks like those welds failed and the brace fell off. That’s my guess. Corsa should cover that

 

[Mgt2]

Well….will see what Corsa says!
this will be my second claim. First was with the active valve making noise and they replaced it, now it’s the muffler.

 

[StangTime]

Doesn’t Corsa have a brace that is welded on at that particular spot (that’s the XX pipe, right?)? It looks like those welds failed and the brace fell off. That’s my guess. Corsa should cover that

This is the correct answer. Maybe corrosion weakened it enough it fell off, or a road debris strike ripped it out or some combo of both.

If Corsa won't replace it, take it to a shop and have a new brace welded in.

 

[Prodigal]

That looks way too uniform on both sides to be random. Something definitely happened in that area at some point.

 

[WD Pro]

Somewhere, on another car forum …

Question - I was following a mustang, heard a clunk, and now the aircon doesn’t work. Found this stuck in the rad, what is it ?

Answer - That looks just like a cross brace off a corsa exhaust …

WD

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