Check your Corsa resonators

[The Tony Show]

I've been hearing a deep rumbling coming from under the car lately (very noticeable if I open my driver's door with the engine running), but couldn't find an exhaust leak. While installing my Kooks headers, my tech found that my Corsa had broken both of the two welds on front of the resonators. It wasn't really noticeable, but when he grabbed the pipe that goes from the front of the resonators to the cats, it spun freely . There was no black soot around the welds like there usually is due to the nature of that weld, but it had to be the cause of the noise.

This may be the only one out there doing this, and I'm not trying to bag on Corsa. Just a public service announcement, so next time you're under the car give those resonators a close look.

[V-Smooth]

You know Tony, I've experienced sound loss and have the deep rumble slightly off idle. It kinda shakes the driver/passenger seat...you can feel it in your seat. The rumble of my Corsa isn't as loud as it was two weeks ago either. I don't know if I have a leak but my Corsa is quieter than normal...gotta climb under it and inspect things...

Is yours bolted or welded in?

[v-ape]

OUCH! I just grabbed mine and it was hot!!!

[ViViDsapper]

I've got a buzz to a rattle from under my car. Corsa exhaust. It usually happens when I get on the gas and get above 3500rpm. It does not happen when I drive normally. I don't know if that is something that I should be worried about or what.

[V-Smooth]

ViViD, I have that too. Kinda like a rattle/buzz, under load its fine. I think the system needs to be welded in to fix that. I plan on taking off all mods when (and if) I sell the car so I dont really want to weld it in...

[The Tony Show]

If you're still using the clamps, they probbly just need to be tightened. I doubt there's many out there that cracked like mine, but my tech commented on how thin the end caps on the center resonators were while he was welding it. He's an experienced welder who worked on several High-rise buildings in Orlando, so he knows what he's doing. He said that the caps are so thin, the original welder probably blew through in a few places due to overheating.

Again- might be the only one in existence, but figured I might be able to help someone find a leak.

[6104696]

the rattle/buzz when revving with Corsa is, I beleive, the small factory heat shield that is bolted to the floorpan in between the exhaust and the rear of the transmission. It doesn't sing under load since the exhaust note doesn't hit the right frequency.

I'm not sure if other exhausts make it sing, too, or if it is just Corsa.

I fixed mine by not revving that high unless driving.......

[Silver Dollar]

I get a buzz/rattle coming from the rear left passanger seat belt buckle.

I'm serious.

[The Tony Show]

You and Gergreg should get together.

Seriously.

[rgd]

At one point I began hearing a rattle in the same place you describe, near the cats. It turned out my cats were gutted. When the dealership went to change them after tech reading showed them as bad they said they were both hollow. They had never seen that before.
I think my new set is almost the same.
I am told driving hard on the track does that to cats.

Poor little kitty! "Sorry Urb", is that why your cat wears a helmet?!

[teros1]

Both of mine are cracked too. Entire bottom half of welds are broken free.

Corsa is sending replacements.

Maybe some sort of flex section would prevent recurence? Or another hanger?

Bob

[The Tony Show]

Glad I could help. Since mine were broken all the way around, it was also making a buzz sound when I'd drive away from a stop. Very annoying.

I don't think an extra hanger is needed, just thicker metal on those end caps. It's so thin that it's really easy to blow through- so much so that my tech had to spot weld a little on one side, then the other, then back again, allowing it to cool in between so he wouldn't heat it too much.