Boxes as received. |
 Warranty information and instructions
were quite complete
although some
attention could have been given to a
few "gotchas" that occur during installation.
|
Nicely packaged and wrapped. |
 Notice the attention to detail and
wrapping.
|
 Spray in foam is used.
|
 I felt like I should have to wash
my hands before handling these.
|
 Yup, all parts are accounted for.
|
 Ah, lifting the car again. I've been here
before. The trick is to
not hurry through
this phase.
|
 Very interesting fasteners, bands
and clamp arrangements.
|
 The hangers are loosened. Four
mid section spring loaded hangers
and two rubber mounted hangers
at the rear attached to the muffler.
|
 Next three bolts holding each bracket
on each side at the front.
|
 The first tube to go in is the passenger
side after the stock
flange is slid off.
Notice, the welded tab on the left above.
There is no captive nut as there is on
the stock exhaust
assembly. Seems
like an oversight. I fixed this a few picture
below.
|
 Passenger side pipe after the
stock flange was removed.
|
 Sanding was advised in the instructions.
I would not have done
this normally but
since the instructions said to....
who am I to not follow instructions.
|
 Here is one of the nuts supplied with
the kit. It is not metric.
That was
disappointing. What was even more
disappointing is me finding that I had
plenty of metric nuts and
bolts this
size later AFTER welding the nut to the
tab.
|
 Welded flange from the bottom
view.
|
 Welded flange from the top view.
|
 A view of the passenger side tube before
adding the "Easy Seal
Clamp".
|
"Easy Seal Clamp" is installed.
|
Sanding the lip of the flange. |
Both of the front tubes are in and
attached
to the front spring hangers.
|
Bolts added to the driver side
flange.
|
 So called center muffler is
next attached (resonator)
|
 A jack handle in place between the
differential housing and the
center muffler.
|
 Next the bands are added. (the
instructions said to put these on
first. I found this too clumsy to
do so I added them after) No big
deal. You just bend them apart to
fix over the
pipe then use a large
pair of channel locks to
bend them back.
|
 Next the "under the axle" pipes and rear
mufflers are hung. This
was not difficult.
What was difficult was aligning
it all up. There were no hints on how to
do this. I just played
with it till things
came into shape then tightened
everything up.
|
 Finally, the last part is clean up
and finding a place to store
the
old exhaust system. You can
see by how much of the system
is protruding that the storage
shelf I used was
very deep.
|
The part that was not so obvious was to affix the very first
pipes put on in the front (head pipes) such that the rear
part of the pipe was slightly lower than you would intuitively
think would be correct. By doing this the rear pipes
do not touch the bottom of the differential case. This would be
bad to find later since a vibration would then exist.
Jacking up the car again to fix this would very annoying.
In closing I would like to acknowledge that many of the things
mentioned above came directly from reading the
ZR1NET. As I started the install and as I progressed through the
project little things would pop in my head that
I had read in other post. The whole project was a piece of cake
because of this.
I hope this was helpful. Who knows I may create a lot more prose
to all this and send it in to be placed in the
Registry magazine.
Here is a link to pictures of a Corsa system that was delivered
with a part that was the
wrong size.
And here is an
MPG file of the management crew recorded shortly after
discovering the wrong part!
