New C4 Exhaust System - More Bark With Your Bite, Part 2 - Tech

We used a tubing cutter to shorten the original A.I.R. tube after the cat converter was bolted firmly in place.

We sacrificed a 5/8-inch box wrench, cutting the handle off short. We also sliced off half of a 5/8-inch, 12-point socket, indexed them so the points aligned, and welded the socket to the shortened box wrench.

The finished job is as pretty as it was difficult. After all the tweaking, the installation looks great, fits well, and doesn't have a single leak or rattle.

Note that the band-type clamps actually conform to the size and shape of the smaller diameter pipe to ensure a positive seal between the two different diameter pipes. We were impressed with this clamping capability.

Bolted up, the Corsa mufflers and pipes are a perfect fit. The entire new system snugs up to the underside of the car so no noticeable ground clearance is lost.

The chrome exhaust tips exit right where the factory tips did. They sit just far enough back to tell folks we have a custom system without being too obvious. The sound is just right, too.