Why do you need a corrugation on the muffler?

Today, the automotive industry is moving forward at tremendous speed. Design solutions that seemed innovative just a few years ago are now completely becoming obsolete. In addition to the rapidly developing direction in the field of automobile design, technological aspects of production are also constantly updated.

One of the goals pursued by engineers is to increase the time between overhauls. Constant work is underway to strengthen vulnerable nodes. One of the stressed vehicle systems is the exhaust system. On the one hand, it works under conditions of constant chemical aggression and high temperature, on the other hand, it is subject to mechanical loads.

Almost all modern cars have a device in the exhaust pipe for damping dynamic loads, the so-called muffler corrugation. Let's take a closer look at what this device is.

How to properly repair a muffler corrugation: design and principle of operation

To date, several corrugation designs are known. The most common among them are two-layer and three-layer. There are also single-layer options, but there is no point in considering them due to their extremely low prevalence.

Double-layer corrugations have two working layers. The outer layer is made of interwoven strands of flat profile wire. The wire has high heat resistance and corrosion resistance. It is also alloyed with additives that increase resistance to fatigue failure.

The inner layer is made of corrugated metal pipe. The second name of this element is bellows. Also made of heat-resistant stainless steel. It has the ability to change its linear dimensions without destruction due to metal folds. The main and only function is the passage of exhaust gases.

Three-layer versions of these devices have an additional inner layer. It comes in two types: braided wire and metal plates. The wire braid is made in the same way as the outer layer. Sometimes it is fixed only on one side and does not perform a supporting function, but only protects the bellows. This is done due to the tendency of the inner layer to narrow in the central part, which leads to a decrease in throughput. Stainless steel metal plates perform only a protective function.

There are flanges on both sides. They are the connecting links with the remaining elements of the exhaust system, and also connect all three layers and secure them. The main properties of flanges are metal strength and good weldability.

The corrugation is designed to dampen vibrations of the exhaust system. The main source of these oscillations is the engine, which, being mounted on rubber cushions, makes cyclic low-amplitude movements during its operation. Also, the rear part of the exhaust system, which in most cases is attached through rubber hangers, moves when the car hits uneven roads.

Why do you need a muffler corrugation?

This element can be called a kind of fuse that protects the exhaust system from vibration that occurs during engine operation. It takes on the main load and is often the one that fails, thereby saving all other parts, and replacing the corrugation is much cheaper than a complete repair of the entire exhaust system.

In addition, the elastic element in the form of a corrugation allows the power unit to move freely in the longitudinal plane. As a result, the load is also removed from other body parts, which is important.

Video - replacing the Chevrolet Aveo muffler corrugation:

In some cases, corrugation is installed during vehicle tuning and allows it to stand out from the background of surrounding cars. From an aesthetic point of view, it does not add beauty to the car, but it protects it from overheating.

A characteristic feature of corrugation is its tightness, as well as the ability to bend, compress and stretch to a certain limit. It can be produced in two versions.

To avoid expensive repairs, it is recommended that any car enthusiast put the car on a pit or overpass at least twice a year and completely inspect the entire underbody, including the exhaust system. This way, you can identify defects in components in the form of scratches or cracks in advance and detect the appearance of corrosion in time.

Double braided corrugation is suitable for power units running on gasoline. At the same time, the braiding from the inside provides protection for the inner surface from mechanical damage. The braid on the outside is stronger and serves to protect against strong compression or vibration, which usually leads to failure of the element.

Triple braided corrugation has higher strength and rigidity due to the intermediate layer, which is a flexible tube. This part is suitable for vehicles with both gasoline and diesel engines. It is also relevant for cars that have already traveled more than 100 thousand kilometers.

In this case, three-layer parts are divided into two more types:

Interlock – the inner layer is made of stainless steel plates.
Innerbraid - the inner layer is made in the form of a braid made of the same steel.

Based on this, the first type of Innerbraid corrugation has a lower cost and therefore has a short service life. Elements of the Interlock type last noticeably longer, but their price is higher.

Replacing the exhaust pipe corrugation: nuances and sequence of work

The corrugation is installed in the front part of the exhaust system. As a rule, it is implanted into the receiving pipe or comes as a separate fragment.

Before installing the corrugation on the muffler, an assessment is made of whether it is possible to cut out the old element without dismantling the entire exhaust system. The on-site replacement method is attractive because it saves money on gaskets, which are almost always disposable, and fasteners, which are rarely stored. Sometimes this type of repair is justified not because of accessibility, but because of extensive corrosion damage to fasteners. It’s easier to cut the corrugation in place than to drill out broken pins later.

Sometimes the corrugation is in a place inaccessible to the cutting tool. Then a section of the exhaust system is dismantled, and a replacement is made at the stand.

In general, a corrugation of the required diameter is selected. Markings are made on the section of the pipe where it is installed. The damaged corrugation is cut out. The edges of the pipe are cleaned. A new spare part is tacked by welding. Afterwards, careful welding is performed around the entire perimeter. The weld seams are covered with paint.

Sometimes owners of cars on which corrugation is not provided for by the design turn to our car service center for service. Basically, these are models from earlier years. Installing a vibration damper will have a beneficial effect on the condition of the exhaust system. In addition, car owners often note the fact of a decrease in noise pollution at high speeds.

Initially, the exhaust system is inspected and the optimal location for installation is determined. Next, a part of the pipe is cut out and the corrugation is welded.

After the work is completed, a guarantee is issued.

Why do you need corrugation?

The muffler corrugation is one of the main components of the exhaust system, acting as an elastic combination between the muffler and the car engine.

Synonyms: flexible connection, vibration compensator, corrugated element.

The muffler corrugation can also be called a fuse that protects the exhaust system and, directly, the muffler. Typically, the corrugation is installed in the receiving pipe or in another area where increased vibration is typical. The tasks of the muffler corrugation include:

Muffling vibrations emanating from the engine to the muffler, contributing to its premature destruction;
Vibration compensation when the car starts;
Be a flexible connecting element in the exhaust system.

In terms of external indicators, the corrugations on the muffler can be said to be identical to each other, with the exception of the diameter. However, in fact, they are divided into several types:

Double layer;
Three-layer;
With double reinforced braid;
With triple reinforced braid.

The durability and quality of performance of the corrugation functions depends precisely on the above indicators. Each of the varieties considered has its own purpose. For example, double braided corrugation is for gasoline engines, and triple braided is for gasoline and diesel engines. The integrity of the corrugation texture affects the ability to prevent exhaust gases from entering the car interior during driving.

Non-repair corrugation on the muffler: why and when is it necessary to replace the exhaust manifold corrugation

There are several main factors by which you can determine that the corrugation needs to be replaced.

Engine vibration. Is a factor taken into account when designing. However, the amplitude of these oscillations often goes beyond the design values. The reason for this may be a malfunction of the engine or destruction of the cushions under it.
High temperature and pressure of exhaust gases. Despite the good resistance to thermal destruction, high temperature has its effect. Even heat-resistant steels can oxidize over time. The situation is further aggravated by pulsating pressure. At the first opportunity, pressure will push through the metal, eaten away by oxidative processes, in a weak spot.
Aggressive chemical effects of the environment and exhaust gases. This factor has the greatest impact in winter, when roads are sprinkled with salt compounds. Exhaust gases contain chemically active compounds that gradually destroy the structure of the metal.
One-time mechanical impact. As a rule, a consequence of operational errors. Hitting an obstacle or parking in reverse and hitting the exhaust pipe can crush or tear the corrugation.

Under the influence of these factors or from natural wear and tear, the corrugation loses its functions. The main faults are:

burnout of the bellows with a violation of the tightness of the exhaust tract;
breakage of the braiding layer with or without destruction of the bellows;
burnouts in the weld area.

Replacing the corrugation on the exhaust pipe: consequences

There are several main consequences of damaged corrugation.

Complete breakage of the exhaust tract. On some cars, such a breakdown will lead to an accident, since the corrugation, while performing its direct function, also supports the exhaust line.
Increased noise pollution, which is not only a distraction, but can also cause an accident. The driver loses the ability to soundly control the road situation due to the roar of the engine.
Penetration of exhaust gases into the vehicle interior. This factor is not only unpleasant, but also dangerous. Exhaust gases contain a large number of chemical compounds that irritate the mucous membrane of the eye, which reduces the driver’s concentration and the ability to fully view the road situation. Also, some substances, such as carbon monoxide, can lead to loss of consciousness when reaching a certain concentration in the body. This factor is aggravated when the corrugation is installed in front of the catalytic converter or if the catalyst has been removed.

What happens if the muffler corrugation becomes unusable?

For corrugation, failure is natural, since it is located in one of the most aggressive zones of the car. The muffler corrugation is constantly exposed to harmful elements and phenomena. In addition, she is entrusted with too many tasks; accordingly, she performs an active function.

The condition of the corrugation is affected not only by the impacts it receives while driving, but also by other phenomena, for example:

Incorrect dismantling of the muffler;
Clogged catalyst;
Gearbox malfunction;
Problems with engine mounts;
Low quality fuel.

Of course, the quality of the corrugation itself and other spare parts affect the functionality of the corrugation and the length of its service life. Therefore, first of all, when choosing corrugation, you should pay attention to the material from which it is made. Typically, black and aluminized steel is used in the production of corrugation.

For many reasons, black steel is not sold in European countries and America. Yes, and domestic shelves are not too littered with it. But, aluminized steel, despite its higher cost, is more attractive to car markets and car enthusiasts, respectively. The advantage of aluminized steel is its high quality, which is explained by its resistance to temperature changes and mechanical stress. If the corrugation suddenly breaks, then there is no point in repairing anything.

Only its complete replacement can rehabilitate the situation, which is characterized by increased fuel consumption and the penetration of exhaust gases into the cabin. And modern cars with a faulty corrugation or its absence can lose their power, since the functionality of the oxygen sensor is impaired.

Replacing corrugations must be taken seriously, as carelessness can lead to more significant damage, the elimination of which will cost many times more than replacing one corrugation.

Varieties of corrugation

In order for a vibration compensator 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 tension of the cylindrical part);
long working life (depends mainly on the quality of the material used).

There are two types of vibration compensators used in the automotive industry. When selecting a part to replace one that has become unusable, you should definitely understand what type of corrugation was installed on this car model:

Vertically installed corrugation.
The vibration compensator is mounted under the exhaust manifold of the vehicle exhaust system. During engine operation, it is deformed by straightening and compression. The length of such a vibration compensator is less than 15 cm, and its internal diameter does not exceed 6.5 cm.

Horizontally installed corrugation.
This type of vibration compensator is predominantly deformed by bending. The part is attached after the 1st elbow of the receiver pipe, counting from the engine. With the same diameter of 6.5 cm, the length of this type of corrugation reaches 40 cm.

Corrugation repair

You can replace the corrugation at almost any car service center. The cost of work varies from 2 to 5 thousand rubles. depending on the make of the car and the type of exhaust system. It takes no more than half an hour. Specialists usually do not undertake to repair corrugation. Therefore, you have to put it in order yourself.

Temporary repairs

In case of minor damage, it is sometimes necessary to bring the corrugation into working condition for a while - before replacing it. The only simple way to do this is to wrap the damaged area with durable material, which is used as:

special heat-resistant tape;
fiberglass fabric;
medical or elastic bandage.

In addition, you will need:

two or three metal clamps;
epoxy resin;
latex gloves;
screwdriver.

During the repair process, the following actions are performed.

The car is installed on the inspection hole.
Access to the damaged corrugation is provided.
The area to be wrapped is cleaned.
The wrapping material is impregnated with epoxy resin and placed on the damaged area.
The winding in two or three is secured with clamps.

For temporary repairs, the damaged area is wrapped with durable material.

It is not recommended to use the car for 24 hours to cure the epoxy resin. After such repairs, the corrugation will last another two to three months.

Most popular manufacturers

There are three types of corrugations on the market:

single-layer, consisting of a metal hose and outer braid;

two-layer, consisting of a metal hose, outer and inner braid;

three-layer (the most popular) - a corrugated two-layer metal hose, an additional rolled inner sleeve and an outer braid.

If we approach the choice of corrugation from the perspective of the manufacturer’s demand, we can distinguish three main companies whose products are present in our car markets:

Hydra

A German manufacturer offering the most durable vibration compensators, characterized by high quality damping of resonant vibrations.

The part has a high level of elasticity, which ensures smooth deformation in any direction vector. This corrugation is often used on German-made cars and on Korean cars with a V-type engine.

Interlock

Polish company with assembly shops in China. Produces three-layer high-quality corrugations that can protect the exhaust system even from sudden jerks. The part has a good safety margin and a long service life.

The material is stainless steel, which is difficult to compress.

Excellent for vehicles with an in-line number of cylinders.

Innerbraid

In fact, corrugations produced by Innerbra >

Choosing in a car store - what to look for

If there is a need to purchase corrugation in an auto store that does not have products from reputable manufacturers, you will have to choose based on inspection and analysis of the offered assortment. Most corrugations on the domestic market come from China. However, this does not mean that all of them are necessarily of poor quality - different Chinese manufacturers offer parts with very different characteristics.

Most corrugations are similar in structure and are divided into only two types: non-reinforced and reinforced.

Inside the reinforced corrugations there is a so-called reinforcement hose, which somewhat extends the service life of the part. At the same time, if the reinforced corrugation is made of low quality steel, the reinforcement hose will not help it much.

The wide variation in the quality of the steel used can be explained by the fact that in production to produce corrugations of the same configuration there is no need to reconfigure machines, and there will still be a buyer for a cheap part, unlike someone who is ready to pay a tidy sum for the highest quality corrugation .

How to choose a part made of high-quality steel? You should pay attention to the following characteristics:

the heavier the corrugation, the better the quality of the material it is made of;
good steel exhibits a “noble” shine - the worse the steel, the more matte it will be;
The corrugations should have thick end rings (caps) - they cook well and last a long time;
The braiding of the part should be as dense as possible - this will provide better load resistance.

Speaking about the density of the braid, special mention should be made of a special class of corrugations - “soft” corrugations for premium cars.

They can be used on Audi, BMW, Mercedes cars. If the model was originally equipped with a “soft” type vibration compensator, you should not try to find a “hard” replacement for it - it will not last long. The reason for this situation is the design features of the exhaust system of certain models of the listed brands.

The average lifespan of high-quality corrugation is 8-10 years. A fake or simply low-quality part will last a maximum of 2-3 years.

Length matters!

Any type of corrugation is placed with an overlap on the pipe. The reason for this design solution is to ensure the integrity of all sections of the pipe leading into the nozzles at the moment when the weld is cut off.

How to replace the muffler corrugation?

Replacement of the muffler corrugation is carried out to maintain an important vehicle system in good condition.

The muffler is one of the most important parts included in a single and integral exhaust system. The main purpose of this unit is to ensure that the noise level generated during engine operation is brought to acceptable parameters and approved state standards. This is achieved by reducing the sound energy of the gases exhausted from the engine by superimposing the incident sound wave on the one reflected from the muffler wall.

General description of the muffler

The product has an oblong oval shape; inside the steel case there are special partitions and chambers that retain the flow of hot exhaust gases, reducing their energy, temperature and pulsation.

In a unified exhaust gas exhaust system, the place of the muffler is after the catalyst (for gasoline engines) or the particulate filter (for power units running on diesel fuel). As a rule, two separately located types of mufflers are installed on modern cars:

Resonator. Here there is a rough forced suppression of noise generated during the operation of the internal combustion engine and fuel combustion. Here there is a relative stabilization of the flow of exhaust gases diverted from the cylinders through the exhaust manifold.
Main building. Here the final suppression of noise and the direction of the slow flow of exhaust gases out of the system occurs.

Muffler corrugation - what is it?

In appearance, the corrugation, one of the parts of the exhaust system, is a flexible, elastic tube, on top of which a metal mesh is applied with a complex layer of interlacing, consisting of many layers. The installation location of the part is between the engine exhaust pipe and the exhaust pipe connected to the muffler. The design of the underbody of the car is such that it is the corrugation that is least protected. This leads to frequent damage to the part when hitting any obstacles. If such damage is received or the part has reached its specified service life, then it must be replaced. Further operation of the vehicle with a faulty (damaged) corrugation cannot be continued.

Purpose of the part

The main purpose of the muffler corrugation is to protect all main components and parts of the exhaust system from destructive vibration. Such vibration occurs during engine operation, it accompanies the car while driving and can cause significant harm not only to the exhaust system itself, but also negatively affect the operation of the engine.

All the main loads that fall on the exhaust system are taken by the muffler corrugation. It is for this reason that it fails more often than other parts. But replacing it is easier and simpler, and most importantly - cheaper, compared to a manifold, catalyst, resonator or muffler body.

Replacing the muffler corrugation

The elastic corrugation is designed in such a way that if damaged or ruptured, it cannot be repaired, but must be replaced entirely. When identifying a malfunction of the corrugation, first of all it is necessary to pay attention to the condition of the catalyst and its serviceability. Very often both elements of the system fail at the same time.

It is recommended to replace the corrugation itself in service centers; this will protect the car owner from possible damage to the exhaust system, leakage, etc.

Replacing the corrugation is practically carried out in the following sequence:

the car is hung on a lift and securely locked;
the positive terminal is disconnected from the battery;
using a grinder, in compliance with all necessary precautions, the corrugation is cut down;
a new part is installed in the vacant space and welding is performed;
the final stage is checking the tightness, carefully processing the welds.

Theoretically, you can replace the muffler corrugation yourself, but only if you have experience, as well as professional tools. In all other cases, it is better to entrust this work to professionals.

Summarize

Every motorist must be very attentive to the good condition of the corrugation, and at the slightest sign of malfunction, take measures to repair and restore the functionality of the part and the entire exhaust system as a whole.

The procedure for performing work when replacing a vibration compensator

Removing a failed corrugation

Before starting work, just in case, you should stock up on new rubber seals that will be installed on the muffler, and a fastening bracket that will hold the receiving pipe on the car body (if such a bracket is used in the design). In addition, you will need seals or gaskets that go under the engine exhaust manifold.

Remove the nuts from the exhaust manifold studs. Also tighten the nuts on the opposite side of the receiving pipe. Remove the loose part.

The old vibration compensator should be removed by cutting it off using a grinder saw.

It is important to do this in such a way that your actions do not compromise the integrity of the flange and the receiving pipe itself. Try to very carefully remove only the welding seam without affecting the rest.

If for some reason you cannot remove a failed vibration compensator with a grinder, try to solve the problem by using a chisel: you can use it to knock off the old weld. Please remember that this operation should be performed with caution.

Mounting a new part

After the old vibration compensator is removed from the car, both parts of the receiver pipe need to be mounted in place and new rubber bands installed on the muffler.

When the receiver pipe parts are secured, spot weld the new corrugation and remove the receiver.

The fixed corrugation can be scalded over the entire diameter of the connection. It is necessary to weld in such a way that the pipes, consisting of two rings placed on top of each other, are connected to each other by their rings. In this case, the outer ring will hold an outer metal braid, which protects the part from external damage.

When the welding work is completed, all that remains is to return the exhaust pipe with new rings and gaskets to its place and put the bracket on top of it.

You can often hear in service stations that a self-installed corrugation does not last long, but in fact the reason is only in the quality of the corrugation itself or in possible non-compliance with the technology and sequence of operations. If all the work is done carefully, a self-installed corrugation will last no less than a part that was installed at a service station.

Video about replacing the muffler corrugation:

Repair and replacement of muffler corrugations are part of the basic services that are provided by almost all service stations. In reality, repairing the muffler corrugation is its replacement, since there is no point in restoring the part. During long-term use, the element burns out, its restoration is ineffective and labor-intensive. Only temporary repairs make sense. Violation of the integrity of the corrugation due to damage is rarely diagnosed; the way to solve the problem is replacement. Changing a part is easy; a welding installation is desirable, but not required.

Replacing the muffler corrugation

Some time ago, only owners of foreign cars could purchase and use corrugation. Now everything has changed and this element can be installed on almost any domestic vehicle of the VAZ series.

Typically, the muffler corrugation is installed in a car service center using professional welding equipment and tools. Installation is complicated because it is necessary to select a certain temperature regime.

Traditionally, work is carried out in several stages:

cutting down old corrugation using a grinder;
welding a new part;
seam processing.

It is recommended to entrust such an operation to specialists with relevant experience. Otherwise, improper installation may adversely affect the service life of the corrugation.

With your own hands

If there is any malfunction, it is not always possible to contact a car service center or there is a desire to carry out repairs only on your own.

In general, the work of replacing a muffler corrugation is not as difficult as it might seem. Only for ordinary car owners it can take several hours, but professionals will spend much less time on it.

Preparation

To make the process easier, it is best to remove the exhaust system pipe along with the corrugation. Using a grinder, cut off the faulty part as close to the welds as possible. To try on a new element, the exhaust pipe is put in place, but not secured, and a corrugation is tried on it. This must be done to avoid the occurrence of distortions in the future, which will lead to unwanted additional load on the part and its rapid failure.

Video - replacing the muffler corrugation with your own hands:

Having outlined the optimal location, it is worth welding two or three points in order to slightly grab the part to the inlet pipes, and then carefully remove the entire pipe.

Welding

Ideally, have a semi-automatic device, with which you can completely forget about the existence of car services. But in its absence, inverter equipment with electrodes with a diameter of 1.6 to 2 mm will do.

Before work, the pipe must be thoroughly cleaned. The welding itself should be carried out with a minimum current value depending on the selected electrode, simultaneously chipping away the slag. At the end of the work, the welds must be treated with some kind of automotive coating (enamel or primer) or sealant.

Since the use of conventional welding equipment is not provided for in this operation, a little training on a thin sheet of metal will not hurt. A regular tin can works well. In this case, the tightness of the seam is very easy to check. If the result is positive, you can move directly to your main job. Otherwise, you still need to learn. It is worth noting that working with an inverter welding machine is difficult, but possible with a certain skill.

Finally, all that remains is to put the exhaust pipe in its place, at the same time replacing the gaskets of the connecting flanges.

No welding

The exact service life of the corrugation cannot be determined, since the operating conditions of the vehicle are taken into account. If you drive carelessly, the corrugation can quickly fail even with high-quality installation. Therefore, welding is not always the best option and in some cases you can do without it. Craftsmen have found one good and effective way.

Threaded connection

After removing the old corrugation by cutting it with a grinder, the new part is put on the prepared place. Several holes with a diameter of no more than 6 mm are made on the rings and exhaust pipe. Next, you need to immediately cut the thread using a tap. When disassembled, all parts, including bolts, must be treated with sealant.

After this, you can begin assembly. The result is a fairly reliable and tight connection. The number of bolts is selected based on the diameter of the exhaust pipe. Usually this is 6-8 pieces.

Stopgap measure

There are times when a new muffler corrugation has already been purchased, but it is not possible to find a time to stop by a car service center.

In this case, one ancient method will help, which requires a medical bandage. But if you need a delay for a full repair for a month, you should purchase an elastic bandage, which is denser and better fixed.

To facilitate access to the damaged corrugation, it is advisable to drive the car into a pit. The bandage should be thoroughly soaked in epoxy resin, and then tightly wrapped around the torn element.

This is a temporary measure that will help the exhaust system last for some time before repair.

The maximum you can count on is a month, no more. Otherwise, parts will literally begin to crumble, and repairs will cost significantly more.

Therefore, a full replacement of the muffler corrugation in such a situation should be planned for the very near future.

Muffler corrugation - what is it?

The corrugation in the muffler is the most important element for removing exhaust gases from the combustion system. It has the form of a corrugated flexible element, alloy steel is used as the base, and a metal mesh is installed on top.

The corrugation in the muffler is the most important element for removing exhaust gases from the combustion system

Many have noticed that when the engine starts, a rattling sound appears from the power plant, which transmits vibration to the muffler. Such influences can seriously compromise the integrity of the gas removal system. The muffler is less susceptible to wear; if you install a corrugation, it dampens vibration shocks and protects the muffler.

On most modern cars, a corrugation is installed; it acts as an elastic connection between the power plant and the gas exhaust system.

Repairing the muffler and replacing the corrugation is most often carried out when elements fail or during regular maintenance, if the percentage of wear does not allow the car to be used until the next inspection. Sometimes they install a “glushak” on their car for tuning.

Muffler corrugation malfunctions

The exhaust system is always subject to wear and tear and is highly vulnerable, as it is located under the bottom of the car. Faulty corrugations cause a lot of problems for car enthusiasts.

The causes of corrugation malfunction may be:

blows;
clogged catalyst;
influence of exhaust gases;
metal rotting due to mud deposits;
wear of engine mounts;
wear of the muffler mounting rubbers.

It is very difficult to protect the corrugation from the influence of all these factors. Some car enthusiasts make and install metal protection on the corrugation, which prevents crushed stone from entering the exhaust pipe area.

With everyday and intensive engine operation, the exhaust system from the inside gradually becomes clogged with deposits and carbon deposits. First of all, the catalyst is susceptible to this. When the catalyst is clogged, if the corrugation is installed in front of it, exhaust gases accumulate, creating strong pressure, leading to rupture of the corrugation.

The walls of the corrugation cannot withstand the pressure load of the exhaust gas, and a rupture occurs

The corrugation may burn out. This occurs after prolonged continuous use of the vehicle and is a “standard” corrugation failure. It is important to understand that due to poor-quality fastening of the exhaust pipe, the corrugation can burn out very often.

For example, if the exhaust system is mechanically damaged, the corrugation may stretch or bend. In this case, its fastenings will be displaced, and the burnout will become chronic. Replacing the corrugation will help solve this problem only for a while. Therefore, before repair or replacement, the entire exhaust system must not deviate from the mounting points.

The temperature and chemical composition of the exhaust lead to burnout of the corrugation

One way to extend the life of a long-suffering exhaust system is to weld the muffler. This part of the car is subject to a barrage of destructive factors, including: sudden temperature changes; aggressive exhaust gas environment; excess moisture; inability to use effective protective and anti-corrosion compounds; mechanical and abrasive damage during movement; constant vibration. As a result, the new muffler turns into a corroding pipe quite quickly. However, you shouldn’t run to the store and buy a new muffler when you can extend the life of the old one.

How to weld a muffler in a garage

Until hints of through corrosion appear in the muffler housing, resonator or exhaust system pipes, there is no need to begin repairing it. When the time comes for repairs, you will hear. With the appearance of “fistulas,” the sound of the running engine changes, smoke begins to spread from under the bottom, often making staying in the cabin unbearable.

The most reliable method of repair is welding. Having the skills to use a welding machine, any car enthusiast can carry out the necessary repairs even in a garage. There is absolutely no point in hiring specialists for this.

To carry out welding work you must have:

welding machine (preferably semi-automatic with wire with a diameter of 1 mm);
a set of automotive tools (wrenches, hammer, screwdrivers);
angle grinder (grinder) with a set of cutting and cleaning discs;
fragments of sheet metal 1-2 mm thick;
metal brushes, sandpaper;
heat-resistant paint for mufflers.

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Repair of the muffler is local in nature, that is, where it burned out, we “patch it” there. Corroded areas are completely removed. After a fragment of the resonator or muffler body is cut out, it is imperative to determine the condition of the internal elements. It often happens that partitions or pipe sections inside the muffler are also destroyed. In this case, you will have to cut out a technological window in the surface of the “barrel” through which the internal parts are restored.

Welding of the muffler or pipes is carried out using a semi-automatic welding machine. This type of welding is more gentle, since the carbon dioxide that accompanies the welding process does not allow the metal to overheat and change its structure. When working on the exhaust system, it is necessary to make continuous welds.

Quite often, through corrosion forms at the junction of the muffler body and the pipe. In this case, it is necessary to completely cut out the corroded section that has become unusable, replace the pipe section and re-weld the muffler.

Painting the muffler after repair can significantly increase its service life. Factories often use low-quality dyes. That is why the exhaust system quickly becomes unusable. If the exhaust pipe has been repaired, care should be taken to further protect it.

To do this, use brushes and abrasive materials to clean all parts of the exhaust, rinse and degrease the surface. For coloring, dyes such as KO 8111, KO 8101, KO 828 or their analogues are used. When selecting paint, it is important that it is specifically designed for surfaces that are heated to high temperatures. These brands are used if it is necessary to paint parts that can heat up to 600º C. The paint is applied by spraying or brushing in 2-3 layers.

New composite materials have begun to appear among drivers' repair kits, which make it possible to repair the exhaust system very quickly. Cold welding for the muffler is available on sale - a special elastic or viscous composition, which, when mixed with a hardener, firmly adheres to the site of damage. To do this, you can use materials such as “Desan”, “Polyrem” or other types of cold welding. Their advantage is fast preparation, rapid hardening, and strong adhesion.

To repair leaky pipes, special bandages are used. The kit includes a “bandage” and a viscous polymer for wetting. A reinforcing layer impregnated with a special composition is wound onto a section of pipe, after which the exhaust system is heated with gases from a running engine. Under conditions of elevated temperature, a very strong connection is formed that tightly closes the hole.

Such compositions are universal, as they glue not only different types of metals, but also glass, wood, and plastic. They are very convenient to use on the road if the service is unavailable. They should be treated no differently than a kind of “ambulance”, but at the first opportunity a full repair of the exhaust system should be carried out.

Why do you need corrugation?

The unit is an auxiliary part of the car, acting as an elastic connecting link. Without it, the comfort of transport will suffer greatly, as it will not be able to meet even the basic conditions of reliability. Installation takes place on the exhaust pipe and the receiving part of the muffler pipe. There are exceptions; sometimes the first connection is installed immediately after the exhaust manifold, and the second after the catalyst.

The location and function of a part often leads to the need for premature work on the item. Wear occurs due to the suspension hitting large obstacles, the bottom clinging to the ground, or exhaustion of resources (number of heating and cooling cycles). The frequency of replacement depends on the operating conditions and the quality of the braid; it is better to buy with 2-3 layers.

The corrugation is an auxiliary part of the car

Role and functions of corrugation:

combating vibrations transmitted from the engine to the muffler;
facilitating longitudinal movements of the power unit in the engine niche;
protection against premature destruction of exhaust system components.

The cost of replacing a muffler corrugation directly depends on the make of the car and design features. For a four-cylinder engine with in-line pistons, 1 corrugation will be required, and for a V-twin engine with 6 cylinders - 2.

Corrugation repair

Temporary repairs

special heat-resistant tape;
fiberglass fabric;
medical or elastic bandage.

In addition, you will need:

two or three metal clamps;
epoxy resin;
latex gloves;
screwdriver.

During the repair process, the following actions are performed.

The car is installed on the inspection hole.
Access to the damaged corrugation is provided.
The area to be wrapped is cleaned.
The wrapping material is impregnated with epoxy resin and placed on the damaged area.
The winding in two or three is secured with clamps.

For temporary repairs, the damaged area is wrapped with durable material.

It is not recommended to use the car for 24 hours to cure the epoxy resin. After such repairs, the corrugation will last another two to three months.

Consequences of corrugation damage

If the corrugation is damaged, gases will begin to leak before they enter the catalyst and resonator, that is, completely unpurified substances will enter the air. Atmospheric pollution increases many times over; if you stay nearby for a long time, you can feel a deterioration in your health.

The bigger problem is the penetration of gases into the car interior; no one would want to drive such a car. The corrugation is located slightly below the engine with an indent towards the center of the car. There are air intake ducts located near the unit, through which gases will likely enter the cabin. Poisoning is unlikely to occur, but comfort will be significantly reduced. If the failure occurs on the road, it is recommended to perform a temporary repair of the muffler corrugation at the nearest station, which will require welding.

High temperature sealant as a temporary solution

This type of muffler corrugation repair is used if a new part is not available. The work is carried out in the following sequence:

the corrugation is covered with a layer of sealant;
a strip with a width equal to the length of the vibration damper is cut out of tin and wrapped in several layers over the sealant;
then it is secured with clamps from the edges and in the center;
After the day required for the sealant to harden, you can drive as before.

Repairing the muffler corrugation with sealant - a temporary solution

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Corrugation repaired in this way will last no more than a month. Some car owners simply cover the damaged area with sealant without wrapping it in tin. In this case, the opportunity to use the car is reduced to two days.

What reasons?

There are few reasons why it is necessary to replace the muffler corrugation without welding: natural wear of the material, the passage of gases or mechanical damage. The following reasons can lead to such conditions:

catalyst damage. If it becomes clogged, thermoregulation disturbances will occur, and during overheating, increased pressure is created in the corrugation;
significant wear of the shock absorber pads on the power unit. The fasteners of the muffler itself are not able to provide sufficient movement of the unit;
deformations due to impacts on the surface;
incorrect installation of the device;
the destructive effects of chemicals that are sprinkled on roads in winter;
use of additives to increase the octane number in gasoline.

What is a muffler corrugation

Many drivers do not know that there is a corrugated part in the exhaust system. They often find out at a car service center when they say that the possible cause of problems in the engine exhaust system is in the muffler corrugation. Corrugation is a flexible product that has elastic deformation. It consists of a flexible tube, which is wrapped in several layers of thin metal wire. The most important advantage of corrugation is its mobility, that is, in order to connect two tubes with it, it is not necessary that they fit exactly together in a certain plane.

Choosing the right corrugation

The muffler corrugation is often replaced and sold at a service station, but you can buy the component at a car dealership. If the owner has the time or desire to carry out repairs on his own, he should initially purchase corrugation. The part is not unified; it is developed individually for most cars. The differences are the dimensions. Before going for the unit, you will need to clarify the size of the element; it is better to find out experimentally - from the pit. Before replacement, it is worth restoring the corrugation and doing the work within the next few days.

When taking measurements, it should be taken into account that you will have to cut the corrugation somewhat further than the weld on which it is fixed. New elements are sold with a slightly reduced diameter for stronger fixation and easier scalding. The corrugation is inserted 3 cm into the pipe, this facilitates repeated replacement of the element on the car without structural changes.

After measuring the length, the diameter is measured. Accurate numbers can only be obtained with a caliper. With known parameters, go to the store or market.

Spare part price

The cost directly depends on the size, model of the car and corrugation parameters. For many low-price cars, the price will be 200–400 rubles. The cost of a unit for more expensive cars reaches 1200, and sometimes exceeds 1500 rubles. During the purchasing process, you should buy 2 gaskets; they are useful for connecting the flange parts to the corrugation. When dismantling the old structure, it is impossible to maintain sufficient quality of the old gaskets; it is better to replace them.

Replacing corrugations with your own hands

Previously, corrugation was a hard-to-find element that was sold separately only for foreign cars; today the market offers spare parts for all types of cars and manufacturers. More often, installation is carried out by specialists using a professional welding machine and other tools. The difficulty lies in the need to determine and select the temperature regime.

If the hand is “stuffed” and the person knows how to work with a power tool, the replacement is carried out in several stages:

Dismantling. Using a grinder, the worn corrugation is cut off.
Installation. Installation of a new part.
Cleaning seams.

Incorrect installation will only temporarily help get rid of problems; the service life of the corrugation will be significantly reduced. It is preferable to leave the operation to specialists, but the task can also be done manually.

Preparation

There are a number of recommendations for quality preparation:

The work will be somewhat easier if you completely dismantle the muffler pipe with corrugation;
“grinder” cut off the knot at the weld or near it;
Trying on the part will help identify possible difficulties in installation and determine that the part really fits. A preliminary assessment will prevent distortions in the structure and protect the spare part from excessive load and premature failure. There is no need to install a corrugated connection at the fitting stage;
After selecting the location, the parts are grabbed at several points to the inlet pipe. Now the whole pipe is removed.

Replacing corrugations with your own hands

Welding

If there is a semi-automatic welding device, there is no need for a service station at all. When there is no equipment, an inverter type is suitable; 1.6–2 mm electrodes are installed in it.

Basic advice from professionals on stages:

Before work is carried out, the pipe, especially the seam area, is thoroughly cleaned.
Welding is carried out with a minimum current. The value is selected taking into account the electrode. During operation, the slag is removed.
Once completed, the welded areas are treated with a protective coating or sealant to prevent corrosion.

The manufacturer does not provide for the use of a standard welding device during the procedure, and given the thinness of the sheet, there is a high risk of burning through the metal. It is recommended to practice in advance on a metal sheet of this thickness. Often a tin can is used as a test; it makes it easy to determine the tightness of the created seam. If the test result is positive, you should start working. Otherwise, it is better to continue training until a high-quality seam is created.

Replacing corrugations using welding

Despite the complexity of working with an inverter device, the task is feasible, but it will require skills. At the end of the work, the pipe is put back in place, and the flanges are changed during the installation process.

No welding

An attractive option for owners is to repair the muffler corrugation with your own hands without welding. It is not always an appropriate installation option, but sometimes it is recommended to eliminate welding. An effective and reliable method without the use of welding has become widespread among the people - the method of creating threads.

The process is carried out in steps:

The cut is made using a grinder.
A new corrugation is installed in place of the old unit.
In the place of the rings and pipes, holes with a diameter of up to 6 mm are drilled. The number of bolts is 6–8 pieces for a standard car, depending on the diameter of the pipe.
Using a tap, apply the thread.
All collapsible parts are covered with sealant: bolts and joints between the corrugation and the pipe.
Install corrugation.

The connection is quite reliable and completely sealed.

Temporary repairs

There is an old method to temporarily repair corrugation using a bandage. To defer for 1 month, you will need a thick elastic bandage. The work is carried out from the pit, since it will be necessary to heat the epoxy resin and treat the element with it. The damaged area is covered with a bandage, and resin is poured over the bandage.

This procedure will last for 1 month or less, then even greater damage will appear. It is preferable to replace the corrugation within a few days or weeks.

Methods for repairing and replacing corrugations

Service station employees are skeptical about the car owner’s decision to replace the vibration damper on his own without welding. Despite this, the connection can be quite reliable if you select the correct corrugation and consistently carry out a series of measures. No specific tools are required. Everything you need is usually in the garage.

Repair with high temperature sealant

The sealant intended for repairing the muffler can be used in repairing the vibration compensator. The procedure is as follows:

Apply sealant to the outside surface of the corrugation.
Wrap the part several times with a strip of thin sheet metal (the width is equal to the length of the bellows).
Secure the sheet metal with clamps in the middle and along the edges.
After a day, the sealant will harden and you can continue driving the car.

Replacing corrugations using clamps

To use this method, you need to select a new corrugation, the length of which is 5 cm greater than the distance between the seams remaining from the broken part. The internal diameter in the corrugated pipes should be 1 mm larger than the diameter of the pipes in the exhaust system. Sequencing:

Place the machine above the inspection hole.
Remove the area with the damaged vibration damper.
Using a grinder, cut off the broken corrugation and remove burrs.
Make a couple of cuts at the ends of the pipes so that they fit snugly against the pipes. Apply sealant over shallow cuts.
Put on the corrugation, fix (but do not tighten) the clamps to correct the position.
Install the part in place, not forgetting to replace the gaskets.
Tighten the clamps. To prevent the nuts from loosening, tap the threads.

Experienced car owners claim that the corrugation holds on clamps no worse than when welded. But there is one drawback - a longitudinal impact can cause the part to jump off the pipe. Therefore, if the car is low-slung, you will have to drive more carefully.

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Threaded connection

Installing a vibration damper with a threaded connection is quite reliable when compared with welding. Preparatory work is the same as listed above. Replacement is carried out in the following order:

A new bellows is installed.
Along the circumference of the pipe, which is put on the exhaust pipe, up to 8 holes with a diameter of 4.2 mm are drilled through at equal distances.
Using an M5 tap, threads are cut into the holes on the pipe, and the holes on the pipe are drilled out to obtain a diameter of 5 mm.
The bolts and holes are treated with sealant, after which one end of the corrugation is secured in place using engraving washers.
Before securing the other end of the corrugation, the structure is assembled and installed on the machine. Next, mark the line where the edge of the pipe is located to avoid skewing.
The structure is removed, holes are drilled and the second pipe is attached.
Test drive.

The threaded connection allows you to avoid going to a service station and still get a high-quality result. The corrugation installed in this way is not afraid of transverse and longitudinal impacts.

Epoxy resin

The use of epoxy resin in the event of a vibration compensator failure is considered a temporary measure. If you urgently need to restore the functionality of your car, but don’t have time to go to a car service center for repairs, you can resort to a simple method of repairing the corrugation. You will need a medical bandage, it is better to take an elastic one. The fabric is impregnated with epoxy resin and then wound onto corrugation. After the composition has hardened, you can use the machine as usual. This method will help for no more than a month. Instead of a bandage, you can use heat-resistant tape or fiberglass.