Exhaust-System Replacement In this segment, the '62 Corvette's exhaust system is completely replaced. Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgraded kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select. Safety Alert: Always wear eye protection when working with power tools or pneumatic tools. With the Corvette on a hydraulic lift, the exhaust system is inspected carefully. Inspection reveals that the exhaust system, including mufflers, tail pipes and header pipes were old and corroded. The decision was made to replace the entire exhaust system with new components. Purchasing a complete replacement system cost about the same as purchasing only the mufflers and tail pipes.
Materials:
Replacement exhaust system (mufflers, header and tail-pipes, connectors and installation hardware)
Standard automotive tools (socket-wrenches, screwdrivers, etc.)
Power wrench
Reciprocating saw
Die-grinder
Chassis spray-paint
Eye protection
Steps:
- Begin the exhaust system overhaul by loosening the nuts on the exhaust manifold, then working the header pipe free.
- Rather than taking the time to separate the pipes, it was decided to simply cut the pipes loose using a reciprocating saw (figures A and B ). Using this technique, it only took a few minutes to remove the entire old exhaust system. For cutting in tight spaces, you may find it helpful to use a die-grinder with a cutting blade.
- Be sure to note carefully how the exhaust system fits together so you'll know how to install the new system. As with other major mechanical overhauls, it may be helpful to take snapshots or digital photos of the old exhaust system beforehand for reference during re-assembly. Also, refer to the Corvette's service manual for instructions with respect to the layout.
- An important component of the exhaust system is the heat riser valve (figure C). This valve is hooked to the exhaust system on the passenger-side manifold. As the valve heats from exhaust gas coming out of the manifold, it opens to allow the exhaust gas to escape. When no hot exhaust-gas is present, the valve closes. If this valve becomes stiff (such as if the car has been in storage for some time), it may fail to open and close properly, and may prevent the car from starting. A new valve is installed as part of the new exhaust system.
- With the old exhaust system pulled from the Corvette, work begins installing the new one. The process is straightforward, but it is a two-person job. Mark and Roger begin by loosely attaching the header pipe and donut gasket to the exhaust manifold, then positioning the first new muffler in place and attaching it to the header pipe (figure D).
- With the muffler in place, the header pipe is tightened gently but securely to the exhaust manifold using a socket wrench and extender (figure E).
- Tighten the pipe clamps to secure the joints of the header pipe and muffler unit (figure F), using caution not to over-tighten the clamp and distort the shape of the pipes.
- Next, tighten down the muffler and exhaust pipe, allowing at least 3/4-inch clearance at all points between the top of the pipe and the undercarriage of the car (figure G).
- With the first muffler and exhaust pipe secured, move on to installing the exhaust system on the passenger side. Install the second header-pipe to the exhaust manifold, making sure to install the heat-riser assembly on this side (figure H). A donut is fitted onto the top of the header pipe end, and then the pipe is fitted into the heat riser. Hand-tighten the connection with bolts using a socket wrench and extender. Keep the connections loose, for now, as you continue installing and adjusting the system.
- Work the muffler unit into position so that it mates up with the header pipe (figure I).
- Once the muffler and pipes are connected together, go back and tighten the bolts at the heat riser.
- Secure the joint between the header-pipe and muffler with a clamp (figure J).
- Secure the muffler to the frame pivot-bracket, making certain that the muffler is secured onto the frame and sitting well under the car.
- Starting from front (with the manifold connections) to back, go back and tighten down all the bolt connections securely.
- With both sides of the exhaust assembly installed, they are checked to see that they match well and are secure. The passenger-side assembly is just slightly lower because of the heat-riser valve (figure K).
In the segment that follows, the wheels and tires on the Corvette are evaluated.
RESOURCES:
Corvette Black Book : 1953-2001
Model: 0933534477
Author: Michael Antonick
Corvette: The American Legend
Model: 0785343741
Author: Consumer Guide Editors
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
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