Found multiple holes in my muffler

[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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[Jjmoberg]

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.

Exactly right. You either need a new brace welded in or they need to send you a new x pipe. Doesnt have anything to do with the muffler.

 

[Mgt2]

Both holes occurred near the 2 braces as showed in the picture(s).
My answer to your question is no. There were no braces in those areas.

 

[Temovic55]

Anyone knows a specific part to look for which will help holding my exhaust especially in the middle section! right after the headers and the resonator ? I keep having leaks between the joints/clamps. I'm boosted and have welded the middle factory resonator once due to rupture ( pressure ) probably overtime caused by the heat and end tip close up valves.
car is having Kooks headers + Roush full exhaust.

 

[Keeffa]

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!

The discoloration looks like something was welded there maybe a brace went across. I would just weld a bit of flat bar back across.

 

[Mgt2]

If it actually caused by condensation it’ll likely happen again in different area(s) of the pipes even if I get it fixed. Would you agree? Corsa would need to figure out why is this happening. Lot of people, including me, have faith in Corsa products and this isn’t a cheap one either. This cat-back costs nearly $3000, I cannot see myself trying to fix a product that is still under warranty.

 

[Snakebyte]

If it actually caused by condensation it’ll likely happen again in different area(s) of the pipes even if I get it fixed. Would you agree? Corsa would need to figure out why is this happening. Lot of people, including me, have faith in Corsa products and this isn’t a cheap one either. This cat-back costs nearly $3000, I cannot see myself trying to fix a product that is still under warranty.

I'll agree with the assessment of others earlier. It appears there was a cross-tube brace originally welded across there. Welding will change the properties of the metal and make it more susceptible to corrosion. In fact, looking at the area around the holes it appears the heat from welding a brace radiated out, causing metallurgical changes. Maybe the welder used an incorrect welding wire which was susceptible to corrosion?????

 

[Mgt2]

Okay, looking at the areas where the holes are what is the logic behind welding in such area?
this Corsa is nearly $3000 and I would be welding on it to accomplish what again?
Once again, I am the only owner of the car and no one drives my car not even my wife.
This hasn’t just happened apparently, condensed water plus pollution have been seating there after each drive and caused it to deteriorate over time or something might have broken loose from the inside.

 

[Nightmonkey]

If someone didn't get under your car with a plasma cutter, then welded-on parts have fallen off because the production process is no good.
So best guess, not only was something welded to the pipe, but the pipe also burned through in the process. Possibly forgotten in the manufacturing process and sizzled onto the pipe without shielding gas in it.

 

[jpjr501]

My car collects so much moisture in that area it actually pees water out of both muffler holes. I'll post a video, it's actually pretty funny.

I bet the moisture destroyed the bracket welds and it flew off somewhere.

Here is what I'm talking about.

 

[robvas]

How is moisture inside the pipe going to hurt a weld on the outside of the pipe? (unless the weld was bad like @Nightmonkey said)

It's 304 stainless and there isn't even any rust there

 

[Mgt2]

Hey man, you deserve a big round of applause ’cause you nailed it. That bracket fell off about a month and half ago while driving on STATE ROAD 200 in my home town. But paid no mind because I didn’t run over anything. That was a clean nice sound I heard when it hits the pavement. Just realized that on the pic you sent.

Now I wonder what might have caused that to fall off like this. Live in Ocala, FL, here the roads are pretty nice and comfortable. The only thing I could think of is that the condensation within the pipes plus pollutions after interstate drives might have caused it to progressively become worse and fell off.

 

[mavisky]

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!

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.

I'm putting my money on you drove over something and it ripped this brace off. This brace is welded on from the factory at Corsa and is just past the bends in the mid-pipe and right before the exhaust clamps leading to the muffler section. That's the exact spot on your exhaust pictured above. You can see the heat marks from the welds from the factory, and the holes in the tubing are almost exactly the size of where the weld would have been around the perimeter of the flat rectangular brace.

You can try a warranty claim, but they may well deny this as it seems much more likely to be the result of impact damage since there doesn't seem to be any signs of corrosion within the damaged area. If it was corrosion that exposed edge of metal on the pipe should be brown and rusty. Since they use a decent quality stainless steel, it's unlikely that corrosion would ever be a concern for this unit.

 

[Mgt2]

If I had driven over something there would be impact in the area(s) where the bracket was welded, right?

 

[mavisky]

Not if the weld penetration wasn't the best I suppose. Hard to say.

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