So, got the Corsa exhaust for the 4.2 I have (2012) and went to do an install. Some may have seen my thread asking about fitment issues. The driver's side flanged pipe was welded wrong. The flange did not match up and was completely off. Corsa did an awesome job of getting one out asap and allowed me to install today.
I've been working on cars a long time. At age 44, I am also a motorcycle road racer and very mechanically inclined. Exhausts are easy. The issue becomes tight quarters and crazy angles. But, this was pretty cut and dry.
Instructions were good. Suggest that they label the part numbers for the pipes that are shown in the drawing layout. This would allow for a quicker layout of the system prior to assembly. But again, there's not a lot to worry about so not a big ordeal.
Bolts and clamps are really nice and great quality.
Outside the issue with the driver's side being wrong, the X-Pipe where it was to join the middle double barrel resognator piece did not match up. The X-Pipe has a welded cross brace as does the mid resognator assembly. This makes it so there is no flex. Which is great. Unless the X-Pipe is squeezed together more than the resognator assembly. Had to clamp and essentially bend the cross brace piece for the pipes to align. This should have been a warning for the remainder of the system...
The two pipes that go from the resognator assembly and the mufflers were also not lining up well which in turn had the mufflers out of whack. I tried and tried with assistance on visually aligning the mufflers so the tail pipes were the same left to right. We used everything we could to maintain the same position for the right and left mufflers and tips. The issue is the two pipes that connect to the muffler are too close together. It's very minimal the difference, but makes the tips on the driver's side rub the inside arch of the lower valance. They also stick out less than that of the passenger side muffler tips.
Looks like total shit and I am really not happy with it. For the money these systems cost and the fact that they are supposedly made in the USA, I would have expected a lot better fitment and craftsmanship. I went back under and tried to align the mufflers again and get that driver's side away from the valance arch but because the pipe is bent wrong, it goes back immediately after driving it. They also stick out differently but not as much of an issue as the rubbing.
I honestly don't know what to do. The system is on, used the clamps, everything is torqued and checked and no leaks. Sounds amazing!!! But the visual of the system is killing me. I really am not sure if I should call Corsa direct and see what they think and any ideas they may have. I think if they would fix that driver's side pipe from resognator assembly to muffler, they could force the muffler out further and more in the middle of the arch as it should be... But what would they say? Tough luck most likely since I am not a professional person doing this...
Anyone have any ideas? Outside taking that pipe off and rebending, assembling, adjusting, trying to bend and move again and repeat often the whole process, should I just see if they will do something? Or am I stuck?
I'll try and take pics and post...
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Originally Posted by Canadianwraith
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