What to do if the muffler corrugation burns out

The muffler corrugation is an important component of the exhaust pipe, without which the engine exhaust system will not be able to function properly.

Corrugation — is a semi-rigid element connecting the vertically downward-facing exhaust manifold to the exhaust system under the vehicle's underbody. Due to its elasticity, it compensates for thermal expansion of the exhaust system and dampens vibration loads.

Externally, it resembles an elastic tube with a multilayer mesh metal weave and acts as an intermediate link between the exhaust pipe and the muffler downpipe. The corrugated pipe is often used to replace a section of a burnt-out exhaust pipe.

Due to its design, the corrugation not only compensates for the vibration that accompanies engine operation, but also dampens the vibrations that occur when starting the car.

Corrugated tubing can come in a variety of designs. It can consist of two or three layers, and have a single or double reinforced braid. In any case, it is made of durable stainless steel.

Despite its strength, the corrugated pipe is quite sensitive to mechanical damage and is subject to wear.

Types of corrugations

In order for a vibration damper to serve for a long time, it must have two main characteristics:

• elasticity (expressed in the optimal combination of the tightness of the corrugated material, the density of the braid and the quality of the tension of the cylindrical part);
• long working life (depends mainly on the quality of the material used).

Two types of vibration dampers are used in the automotive industry. When selecting a replacement part for a worn-out one, it's essential to determine which type of damper was installed on the vehicle model in question:

1. Vertically installed corrugated pipe. The vibration damper is mounted under the exhaust manifold of a vehicle's exhaust system. During engine operation, the exhaust system undergoes both extension and compression. The length of this vibration damper is less than 15 cm, and its internal diameter does not exceed 6.5 cm.
2. Horizontally installed corrugated pipe. This type of vibration damper is primarily deformed by bending. The part is attached after the first elbow of the intake pipe, measured from the engine. With the same diameter of 6.5 cm, the corrugated pipe length of this type reaches 40 cm.

The corrugated pipe burned out - what to do?

Burnout is a common problem with all muffler components. A burnt-out part no longer performs its intended function, leading to uncomfortable driving and can even pose a danger to the driver.

Unfortunately, no corrugated pipe can be completely repaired, so there are only two options for fixing a burnt-out element:

• Change together with the pipe.
• Change separately, leave the pipe as is.

Installing a new corrugated pipe

Once the new part has been purchased, we can get to work. Replacing the muffler corrugation isn't a particularly difficult job, but it can take several hours for a non-expert. Remove the exhaust system section. Using an angle grinder with a cutting disc, cut off the damaged section as close to the original weld as possible.

After this, we put the pipe back in place and insert the new corrugated pipe. This is necessary (especially if you're doing the job for the first time) to ensure the new muffler corrugated pipe fits correctly, as this would place additional stress on it and reduce its service life.

Mounting a new part

After the old vibration damper has been removed from the vehicle, both parts of the intake pipe must be reinstalled and new rubber bands must be installed on the muffler.

The vibration compensator being installed must be mounted into the system so that it stands freely and is not under stress due to compression, tension, or bending.

Welding works

Ideally, a semiautomatic welding machine with a wire feed should be used for this procedure. However, in the latter case, you probably wouldn't even consider calling a service center to replace the corrugated pipe. However, if you or your friends don't have a semiautomatic welding machine, you'll have to choose this option.

Car enthusiasts who lack the resources or the necessary skills often turn to professionals. Some may assume that welding an exhaust system will be easier, but they don't consider the equipment and experience required for this type of work. A reputable auto repair shop will undoubtedly have all of these skills.

Replacing the corrugated pipe at a car service center

You can replace a muffler corrugated pipe at any auto repair shop, but it's best to have it done at reputable auto repair shops that provide high-quality service. The cost varies depending on the car make and type of exhaust system. The procedure takes no more than half an hour. Professionals can also repair it, but the best option is to replace it with a new one.