At Mid America Motorworks'...
At Mid America Motorworks' Corvette Funfest, Corsa Installs New C5/C6 Exhaust Systems As Quick As They Can Get Cars On The Lift.
Last year, at the Mid America Motorworks Corvette Funfest-a 10,000-plus all-Corvette car show held annually every September in Effingham, Illinois-we ran across a sight not seen anywhere else. Every year, tons of attendees decide to have their new cat-back exhaust system installed "while they wait." Multiple manufacturers with multiple car lifts, all set up in the MAM parking lot, accommodate row after row of Vettes, all parked and waiting their turn. After timing several companies, we noticed the Corsa boys completed the OE removal and replacement of their system in about 20-25 minutes. Wow! We decided right then and there to follow along on the next car to show you how to do the job on your own.
When we walked up, Mark Bockwich of Corsa Performance Exhausts, with Steve Ali of Xtreme Performance lending a hand, were about to install a new Corsa system on a black '05 C6 coupe. We asked Mark what the primary differences are on the systems they sell. He said, "There are two different sound levels for our systems: Sport and Touring. Sport is a little more aggressive. Touring is a little bit quieter, but they both have no drone whatsoever inside the cab. The aim is to increase the decibel level without adding a drone." Jeff Makovich, sales representative at Corsa, later claimed horsepower increases of 13-14 rear-wheel horsepower with these systems.
Mark explained the procedure they were using as he started the next install. "Using a lift really simplifies the job. Then, basically, all you need is a pipe cutter (for automatic cars only), a set of wrenches and assorted tools, plus a little know-how. Just watch me in this install and take some notes." Fair enough. Let's all watch and learn.
| Difficulty Index - 2 Wrenches |
| Anyone's Project: no tools required | 1 Wrench |
| Beginner: basic tools | 2 Wrenches |
| Experienced: special tools | 3 Wrenches |
| Accomplished: special tools and outside help | 4 Wrenches |
| Professionals Only: send this work out | 5 Wrenches |
On automatic cars, cut the...
On automatic cars, cut the passenger side pipe behind the rear clamp and before the pipe goes over the rear axle. Mark uses a chain-style cutter, which makes a neater cut than a hand saw. On stick-shift cars, this cut is not necessary due to larger clearance tolerances that enable the pipes to be removed.
You will need to drop the...
You will need to drop the rear stabilizer bar. Back off the 18mm bolt on the bottom of each clamp (one per side). The upper stabilizer bolt has no nut on the back.
Now swing the stabilizer bar...
Now swing the stabilizer bar out of the way. (There's no need to completely remove it.)
Loosen the clamp to the over-the-axle...
Loosen the clamp to the over-the-axle pipe and factory H-pipe. there's one pipe per side.
Loosen the four bolts that...
Loosen the four bolts that hold the factory H-pipe to the catalytic converter flange.
Remove the two 13mm spring...
Remove the two 13mm spring hanger bolts located in the middle of the H-pipe.
Now remove the H-pipe and...
Now remove the H-pipe and set it out of the way. You'll re-use it.
The rear hangers (one per...
The rear hangers (one per muffler) ride in rubber grommets. Use a water-based lubricant (soap and water, or Windex) to facilitate sliding the hangers out of their rubber grommets.
Wiggle the mufflers and over-the-axle...
Wiggle the mufflers and over-the-axle pipes out of the car.
Re-install the H-pipe
You now reverse the OE exhaust...
You now reverse the OE exhaust removal steps. As you tighten the catalytic converter flanges, check for clearance between the pipes and the framerails.
Snug up the 13mm spring hanger...
Snug up the 13mm spring hanger bolts.
A new set of Corsa axle-back...
A new set of Corsa axle-back exhausts, which consist of a set of the Sport mufflers, polished tips, and over-the-axle pipes.
Insert the over-the-axle ...
Insert the over-the-axle pipes.
Slide the over-the-axle pipe...
Slide the over-the-axle pipe into the factory H-pipe on the passenger side and tighten the clamp. Just snug the clamps but don't tighten them. Do the same to the driver's side.
The clamp on the backside...
The clamp on the backside of the Corsa muffler goes on 90-degrees to the notch, as seen here.
Now slide the new mufflers...
Now slide the new mufflers into place. Notice how the hanger slides into the rubber isolator.
Insert the second muffler...
Insert the second muffler.
To tighten the clamps, you'll...
To tighten the clamps, you'll need a long extension.
Now reattach the sway bar....
Now reattach the sway bar. Torque on the sway bar is 50 psi on the upper bolt and 70 psi on the lower.
Now loosen the clamps behind...
Now loosen the clamps behind the muffler, and rotate the tips clockwise or counterclockwise to get a nice horizontal level.
The tips are now aligned,...
The tips are now aligned, and the installation is finished.
Comparing the OE Muffler to...
Comparing the OE Muffler to the Corsa Sport Muffler
A cutaway of a stock C6 muffler reveals fiberglass "hair" and a perforated tube to muffle sound.
The Corsa muffler is made...
The Corsa muffler is made entirely of high-grade stainless steel. Interior passageways cancel out the "wah-wah-wah" drone that would otherwise invade the passenger space.
Corsa tips resemble chrome,...
Corsa tips resemble chrome, but are actually hand-polished stainless steel. Double-welds create a space inside to dissipate heat and prevent the tips from turning color.