Do-it-yourself repair and replacement of muffler corrugations: what is it for?

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In order to provide a flexible shock-absorbing connection between the engine and the muffler, a corrugation (vibration compensator) is used. The device dampens engine vibration, so the exhaust system can be rigidly attached to the car body. But vibration quickly destroys metal weaving. The unprotected corrugation located under the bottom is exposed to mechanical and chemical influences from the external environment.

Drivers of old cars ask, why do we need corrugation? The answer to this question is known to the owners of some VAZ car models that do not have a vibration compensator. The craftsmen who installed it themselves felt the difference. Vibration and noise in the cabin have become much quieter, and at idle the engine noise is almost inaudible.

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.

Causes and symptoms of muffler corrugation malfunction

Corrugation damage is often associated with mechanical stress. This may include impacts from bumps and rocks, as well as wear and tear over time. Other causes of damage include poor condition of the transmission, worn rubber in the muffler mounts, and improper installation. Reagents used on roads by public utilities destroy metal. Additives in automobile fuel also work.

The main sign of a bellows malfunction is an unusual sound when starting the engine and when driving. In addition, the following signs indicate a malfunction:

• reduction in engine power;
• car popping and sneezing;
• instability of the rhythm of the running motor;
• penetration of exhaust into the cabin;
• the appearance of soot on metal components.

If the above symptoms are detected, it is necessary to replace the corrugation. There are several methods, the choice of which determines the life of the machine.

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.

Types of corrugation

Corrugations come with two-layer and three-layer braids. The former are used in gasoline engine systems. The inner layer, thinner, is designed to protect against thermal influences from the inside. The outer layer is much tougher. It is needed to dampen vibrations and protect against compression.

Three-layer car muffler corrugations are universal and can be used in conjunction with gasoline and diesel engines. The middle layer in them is made in the form of an elastic corrugated tube.

Three-layer muffler corrugations are divided into two types:

• Innerbraid - the inner layer is made of metal braid.
• Interlock - the inner layer is made of metal plates that form a sleeve.

Interlock corrugation is stronger, more flexible, more durable, but much more expensive. Innerbraids are usually offered on the aftermarket. Also, corrugations may differ in purpose. In some cars, the muffler corrugation is installed vertically. In this case, it works on compression and straightening. When mounted vertically, a reinforced corrugation with an internal diameter of 65 mm and a length of no more than 150 mm is installed. The new part must exactly match the dimensions of the failed corrugation.

Horizontally installed vibration compensators work for bending and have a length of up to 40 cm. During installation, a slight discrepancy in length compared to the original is allowed.

Welding corrugations into a car muffler

The most labor-intensive and reliable process of replacing the vibration compensator of the exhaust system.

Let us immediately note that only professionals are allowed to carry out welding work, so we do not recommend taking on such a complex task on your own. But if you have the proper experience and want to learn the nuances of the process, then our video will be very useful for you. From the video you will learn what mistake should never be made, how to install the corrugation correctly and which products are more reliable.

Video explaining all the nuances

Possible repair of a faulty element

Due to the tightness of the product itself, repairs in case of severe ruptures and burnouts are not possible.

However, in some situations you can save on buying a new part of the system and repair the device yourself.

Temporary measures

The key to successful operation of the exhaust system is its complete tightness.

The same applies to corrugation. In order to quickly eliminate the deformation that has begun, you can use special sealants for mufflers.

These substances perfectly close all holes or cracks, ensuring tightness even at the highest temperatures.

Bandaging

Temporary repairs also include the use of bandages.

A special bandage tape made of thin foil is applied to the pipe.

The tape covers cracks and holes, allowing you to ride this muffler for some time:

Heat-resistant material allows you to extend the service life of the corrugation for some time

How to weld using electric welding

Self-repair using a welding machine is possible if you have experience in welding.

If the car owner is not confident in his abilities or has only basic skills, then it is better not to take risks, as it is easy to damage the muffler pipes.

Sometimes, after hitting an uneven road, the corrugation may “move away” from the pipe - in this case, it is necessary to weld it again.

For these purposes, two types of electrodes are usually used - with a diameter of 3 and 4 mm:

1. The corrugation is grabbed along the diameter of the pipe with a 3 mm electrode.
2. The correctness of its fixation is checked (the product must be located strictly in the center of the pipe).
3. Next, the entire circumference of the pipe diameter is welded with 4 mm electrodes.
4. After the weld has cooled, it is necessary to clean it and paint it with heat-resistant paint.

The seam when welding corrugation must be smooth and uniform

You need to work with electric welding very carefully, as you can burn extra holes in the metal of the pipe.

What to pay attention to

What should you consider before installing a new corrugation? Try to understand the reason for the breakdown of the old corrugation.

When an old part failed due to the fact that a large load was placed on it, but it could not stand it. Then this malfunction should be eliminated in the car. Otherwise, the same fate will befall the new corrugation.

For example, when the engine mount is worn out, when the rubber fasteners of the muffler are stretched. The load on the corrugation is increased, and it may well break and burn out due to the fact that it operates in a mode not intended for its functionality.

Is repair possible?

If the muffler corrugation is burnt out or out of order, then there is no point in repairing or restoring it; only replacement will help. Of course, there are folk “craftsmen” who manage to somehow repair corrugations. But such would-be craftsmen should be sent away, because the design features of the part do not allow this to be done efficiently.

Repair or replacement of muffler corrugation?

On a note! The average service life of a new corrugation is 2-3 years, but this depends on the quality of the installed part.

How to change the corrugation on the muffler yourself

We recommend that you contact specialized centers for this work so that the work is performed at a professional level. But if this is not possible, then you can replace the muffler corrugation yourself.

Methods of restoration and replacement:

1. Welding corrugations;
2. Winding the damaged area is the fastest and most short-lived option.
3. Changing the part using a special heat-resistant sealant;
4. Replacement by screwing;
5. Using clamps.

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.

Epoxy resin

This is also a temporary measure that allows you to restore the functionality of the vibration compensator within an hour. They use it when there is no time to visit a service station. Repairs are performed using a regular medical bandage, preferably an elastic one. It is impregnated with epoxy resin and tightly wound around the corrugation. After waiting for it to harden, use the car as usual. Epoxy resin will last no more than a month. As an alternative, you can use fiberglass or special heat-resistant tape.

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.

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.

Muffler corrugations

Reasons for failure

In addition to the fact that the corrugation takes on powerful mechanical loads, exhaust gases with a temperature of 300-900°C are passed through it. The aggressive chemical environment at this temperature burns through the braids over time. The car will inform you about this with a loud rumble. The burnt part will have to be replaced.

Corrugations, especially not original ones, quickly and inevitably rust until a gap forms in the wicker wall. The lower the vehicle's ground clearance, the greater the likelihood that the corrugation will be damaged mechanically when hitting an edge, stone, etc.

Replacing the muffler corrugation

The replacement procedure can be divided into several stages. This is dismantling the old corrugation using a grinder, installing a new element and processing the welding seams. In order for the corrugation to last as long as possible, all actions must be performed correctly. Everything must start with the preparatory process.

Replacing the muffler corrugation

Preparation

To make the work easier, it is advisable to remove the entire pipe with corrugation, and then change this element. This will also give you the opportunity to inspect other parts of the exhaust system and replace them if necessary. To work, you need to prepare an angle grinder, a welding machine, a set of keys and a new corrugation. Only after you have everything you need at hand and the corrugated pipe has been removed, you can begin replacement.

Removing the exhaust pipe

Step-by-step instruction

The replacement process is simple if you understand this issue. Below are detailed instructions for replacing the vibration compensator, following which you will be able to complete the job without any problems or difficulties.

Step 1 . Remove the battery terminal. This must be done before starting any welding work on the car.

Removing the battery terminal

Step 2. Inspect the muffler corrugation.

Visual inspection of the muffler corrugation

Step 3. Remove the corrugated pipe. To do this, you need to unscrew the fasteners that are most likely stuck. In such cases, you need to use WD-40. Before removal, you need to disconnect the lambda probe.

Exhaust pipe removed

Step 4. Make marks on the pipe where you cut. Chalk or marker - it doesn't matter.

Markings on the exhaust pipe

Step 5. Cut out the old corrugation using a grinder.

Cutting out old corrugation

Step 6. Try to cut as evenly as possible, so that later it will be easier to join the metal and weld it.

Smooth and neat cut

Step 7. Clean the cut area, making it as even as possible.

Cleaning the cut area

Step 8. Place the corrugation at the joint and begin welding.

Welding corrugation with pipe

Step 9. The welding seam should be smooth and without gaps so that smoke does not leak out.

The seam should be smooth and without gaps

Step 10. One edge of the corrugation is welded and completely ready.

The corrugation is welded on one side

On a note! If you do not have experience in welding, you can ask a friend or acquaintance for this purpose.

Step 11. Cut the corrugation on another part of the pipe and clean the cut area in the same way. Tack welding and welding must be done on site so that there is no distortion.

The second end of the pipe is cut and stripped

Step 12: Fit the edge of the pipe that is not yet welded. The same must be done with the other part of the exhaust.

Exhaust pipe fitting

Step 13. Make several clamps in a circle, and then remove the now solid pipe for subsequent work.

Performing multiple tack welding

Step 14. Weld the second end of the corrugation and, having processed the welding seam, proceed to install the exhaust.

Welding the second end of the corrugation

Step 15. The corrugation is replaced and the pipe is installed! At the same time, you can change the gasket.

Install the pipe with the replaced corrugation

Step 16. Don't forget to connect the lambda probe. This is the end of replacing the corrugation! All that remains is to start the engine and evaluate the quality of the welds.

Connect the lambda probe

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.

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:

1. Apply sealant to the outside surface of the corrugation.
2. Wrap the part several times with a strip of thin sheet metal (the width is equal to the length of the bellows).
3. Secure the sheet metal with clamps in the middle and along the edges.
4. 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:

1. Place the machine above the inspection hole.
2. Remove the area with the damaged vibration damper.
3. Using a grinder, cut off the broken corrugation and remove burrs.
4. Make a couple of cuts at the ends of the pipes so that they fit snugly against the pipes. Apply sealant over shallow cuts.
5. Put on the corrugation, fix (but do not tighten) the clamps to correct the position.
6. Install the part in place, not forgetting to replace the gaskets.
7. 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:

1. A new bellows is installed.
2. 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.
3. 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.
4. The bolts and holes are treated with sealant, after which one end of the corrugation is secured in place using engraving washers.
5. 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.
6. The structure is removed, holes are drilled and the second pipe is attached.
7. 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.