Replacing the muffler corrugation with your own hands and at home

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The operation of a car engine is accompanied by significant vibrations, which are transmitted to the exhaust system. To compensate for these vibrations, a muffler corrugation is used as a flexible connecting element in the exhaust system. It is installed on the exhaust pipe or other areas where high vibration loads are observed.

Using a muffler corrugation helps solve several problems simultaneously, namely:

• dampen vibrations that occur when the engine is running;
• connect the exhaust system elements together;
• prevent destruction of exhaust system elements due to deviations at the time of vehicle start.

The muffler corrugation is also called a flexible connection or vibration compensator. Sometimes it is used as a material for building up a burnt-out exhaust pipe.

This spare part is very important for the machine, as it reduces all engine vibrations that occur during operation.
See also:

How to make a muffler for a car with your own hands

What is a muffler corrugation and why is it needed?

The corrugation, as part of the exhaust gas system, is a metal coupling that connects to the muffler pipes. For a modern automaker, corrugation is a basic design element.

The function of the muffler corrugation is to dampen vibrations that occur during engine operation, especially at startup. Thanks to this, the elements of the exhaust exhaust system deteriorate much more slowly. The corrugation is also a kind of connecting part between several components of the exhaust system, ensuring reliable contact.

Causes of breakdowns and combustion

The corrugation fails earlier than other parts. Stones, hummocks, curbs, etc. can catch the corrugation and tear it.

In addition to external influences, the corrugation is damaged due to strong engine vibration. The internal combustion engine begins to vibrate strongly as a result of friction (when one cylinder does not work) or the engine mount is loosened and it has an increased amplitude during operation. Due to strong vibration, a large tensile force acts on the corrugation.

In addition to mechanical influences, the corrugation is subject to physical and chemical influences. The design of the car also has a catalyst that monitors exhaust gases. If the catalyst is clogged, hot CO2 gases begin to accumulate and create holes in the corrugation.

If the corrugation braid is damaged, the entire corrugation should be replaced. The muffler corrugation is a disposable part, a consumable item.

The corrugation material for the muffler is high-alloy stainless steel.

What can cause a malfunction of the muffler corrugation?

Untimely replacement of a burnt or broken muffler corrugation can lead to the following consequences:

• Possible entry of some exhaust gases into the cabin.
• Overheating of the muffler, which will gradually lead to mechanical damage or deformation.
• Increased noise level during operation of the exhaust system.
• If the seal of the corrugation installed in front of the catalyst is broken, air will be sucked into the exhaust system, which can “mislead” the oxygen level sensor. This will provoke an increase in fuel consumption, as the sensor will begin to send a signal to the system to increase the enrichment of the fuel mixture. The most unfavorable result of this may be the failure of the converter.

The corrugation is exposed to serious mechanical, temperature and chemical loads and is the most vulnerable element of the vehicle exhaust system; accordingly, it must be changed relatively often.

Why do you need a corrugation on a muffler?

The corrugation in an automobile exhaust system is a fuse that does not transmit vibration from a running engine due to its flexibility. Thanks to the corrugation, the rest of the exhaust pipes following it do not shake or deteriorate. Replacing the corrugation is cheaper than repairing the entire system.

The presence of corrugation does not affect the appearance in any way. Therefore, they tune it by installing corrugations to protect the pipes from overheating.

Advantages of corrugation:

• flexibility;
• compression;
• stretching

To conduct a visual inspection, it is recommended to park the car in a pit or on an overpass 2 times a year and inspect the underbody and all parts.

Double braided corrugation

Double-braided corrugations are suitable for cars with gasoline internal combustion engines. The inner layer of wire winding protects against mechanical damage. The outer layer of the winding protects against rupture when the corrugation is strongly compressed. The outer braid is much stronger.

Triple braided corrugation

This corrugation, which has 3 layers of winding, is stronger due to the intermediate layer. Provides high strength and rigidity of the product. This corrugation is installed on both diesel and gasoline engines. In addition, for internal combustion engines with high mileage, more than 100 thousand km. Corrugation with triple winding is the best option.

Classification of three-layer corrugation by type:

1. Interlock (English: inter
   - inside,
   lock
   - blocking). This means that the inner layer is made of a steel plate in the form of a flexible sleeve.
2. Innerbraid (English: inner
   - internal,
   braid
   - braid). This means that the inner layer is made of wrapped steel wire.

The first option, Interlock corrugation has a longer service life. The second option, which is with braid, is cheaper and has a shorter lifespan. In addition, there are reviews that the inner braid breaks and rattles, which is annoying.

Signs of a malfunctioning muffler corrugation

In order to prevent failure of serious elements of the exhaust system, you need to know what the signs of a malfunction of the muffler corrugation are. Among them:

• high noise level of a running engine;
• rattling metallic sound in the area of ​​the engine exhaust pipe;
• decreased engine traction power, increased fuel consumption.

These symptoms may also indicate other vehicle problems. To confirm the “diagnosis” it is necessary to visually verify that the corrugation has become unusable. Cracks will be visible on it, or it will simply be torn off at the joint.

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.

Which is better to buy a muffler corrugation?

Manufacturers offer 2 design options for muffler corrugations:

• Innerbraid. The corrugation wall is three-layer. The corrugated layer is located between two braids.
• Interlock. It has an additional inner layer, which is a flexible steel tube.

Interlock corrugations are stronger and more durable, however they are 20-30% more expensive. If your car has a powerful, thirsty engine and is operated in not the best road conditions, then it would be wiser to spend an extra hundred rubles and purchase Interlock corrugation.

It is also worth paying attention to the reputation of the manufacturer.
For example, muffler corrugations produced by FORTLUFT and BOSAL are of high quality material and workmanship, so they wear out for quite a long time. And this at a more than adequate price. You can read more about this manufacturer here. You can purchase such corrugation in any IXORA store, as well as in our online store. Our experienced consultants will answer any questions you may have. * Please check the applicability of parts specifically for your car with our managers by phone (calls within Russia are free).

To see how the corrugation is replaced, see the video below.

Cable corrugation, sizes, prices

Corrugated pipes for electrical networks are available in sizes from 16 mm to 65 mm. When choosing a size, you need to take into account that these products have two diameters - outer and inner. If you are going to lay several conductors - wires or cables - the diameter must be selected so that there is a clearance of at least half the radius. This requirement is based on the fact that when installed in groups (it is necessary, by the way, to take a special cable), it will heat up more and the presence of an air gap will contribute to better heat dissipation.

The price of corrugated electrical pipes depends on many factors

Size selection

The choice of corrugation diameter also depends on the area where it will be laid:

• for lighting fixtures - 16 mm;
• to sockets and switches - at least 20 mm;
• from the main distribution box to the next box, from the shield - at least 25 mm;
• the connection between two electrical panels is at least 32 mm, and it is better to have a spare second line;
• passage through the floors with rigid corrugation of at least 40 mm in diameter;
• laying low-current cables (telephone, internet, antenna, etc.) - from 25 mm.

The diameter of the corrugation for laying the cable is selected depending on the number and cross-section of wires. Data for copper conductors are given in the table.

Table for choosing the diameter of the corrugation for cables and wires depending on the cross-section and number of wires

This information is for reference only, but you can use it as a guide. You can take a larger, but not smaller diameter.

Prices

Generally speaking, the cheapest is PVC cable corrugation, in the middle range - PP and HDPE, and the most expensive is metal corrugation. Moreover, the option with broaching is slightly more expensive than without it

When purchasing, you need to pay attention to the same wall thickness and color uniformity

Different materials, colors, wall thicknesses and different prices

Corrugated cables are sold in coils of 50 and 100 meters, less often you can find them in meters, but the price is then a little higher. In general, the price depends not only on the material, but also on the wall thickness. The cheapest is lightweight PVC corrugated cable, but sometimes it looks more like just a film. It’s hard to say what this can protect against. If you care about quality, it is better to purchase everything related to electrical equipment not in construction supermarkets like Leroy, etc. and in specialized ones. The quality there is usually better, and the prices, if higher, are reasonable. To give you an idea of ​​the possible price range, we will summarize several types of corrugation with brief technical characteristics in the table.

How much does a flexible muffler connection (corrugation) cost?

The exhaust system corrugation is not a universal part; it is selected specifically for the car. Therefore, prices for muffler corrugations have a certain range. Our car service offers a wide range of corrugations, different sizes and variations.

• Approximate prices range from 400 to 2000 rubles.

Conventional versions of flexible connections, without reinforcement, will serve well on domestic and foreign-made vehicles moderately used in comfortable urban conditions. For racing cars and sports cars, you will need a more durable option.

• We are ready to offer the most optimized corrugations, reinforced with steel plates on the inside, at a price from 2,000 to 10,000 rubles.
• We have muffler corrugations for large vehicles: tractors, dump trucks, trucks . Prices - from 1000 to 3000 rubles.

All corrugations presented in our warehouse are certified goods produced by well-known European, American and Asian manufacturers. We are an official dealer of brands such as Hydra , Masuma , Eberspacher and many others. Here you will find domestically produced products, corrugations from PROSPORT , which are distinguished by a reasonable price and decent technical characteristics.

Exhaust system corrugation