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2

The ultimate fix for failures caused by corrosion, is a stainless steel exhaust system. As for causes: Driving on salty roads (near the sea? Or harsh winters?) Many short journeys (exhaust doesn't get hot enough, water and exhaust acids don't get expelled but sit around in the exhaust rotting it from the inside out) High sulphur fuel (creates more acids ...


2

Welds on steel exhausts are not protected Exhausts are normally constructed from galvanised steel. Welding breaks through the galvanized protective layer though, so every weld in an exhaust is a corrosion point. It would be possible to galvanise the pipe on the outside after welding, and exhausts fitted by manufacturers usually are, so that the car can ...


3

I replaced the same section of rusted pipe over and over again (two feet behind the catalytic converter), whereas the rest of the system, including the mufflers, lasted for decades. I found it was due to water collecting there; I could understand/guess that the water puddled there due to the angle of my pipes. Also, my daily commute was under 15 minutes in ...


1

It's caused by the combustion products. When hydrocarbons combust, they produce two main combustion products: carbon dioxide and water (plus some pollutants that are being removed by the catalytic converter). Carbon dioxide, as we know, causes climate change. Water on the other hand causes rust in your exhaust pipe. There is no possibility to prevent the ...


7

For more than 25 years most auto exhaust systems have been 13 chrome stainless. I have never seen one corrode significantly; I have driven at lease 3 vehicles to about 130,000. So unless you are using carbon steel exhaust or leaded gasoline it is a very unusual problem. Leaded gasoline had bromine added to carry lead out of the engine, it made acid which ate ...


28

Another cause of rapid exhaust system rusting is driving patterns which don't warm up the vehicle thoroughly. In this case, a "thorough" warmup means the entire exhaust is hot enough to cause all moisture within to evaporate. Depending upon the vehicle, this might take 10 miles of driving, the sort of distance necessary to warm the oil (not the ...


13

3 in 4 years? That sounds like the engine mounts were loose or broken and putting undue strain on the pipe. Another possibility is hitting the exhaust on sleeping policemen - are the roads in good condition - lots of potholes etc can also cause flexing damage. Making sure all the mounting points and rubbers are in good condition is another thing to check.


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