C6 ZR1 Exhaust System - Pipes In The Fast Lane

The factory crossover pipe assembly is a slip-on type, allowing Bockwich to easily slide it away from the converter pipes. This is necessary to allow the factory mufflers to be removed from the vehicle.

Bockwich cuts the factory over-axle pipe (passenger side only), giving it more exit clearance and making its removal quick, easy, and safe. This step is critical to the procedure because it minimizes the chance of damaging the fuel and vapor-return lines, as well as the myriad wiring that runs along the underbody. Corsa suggests using a chain-style cutter for slicing through the pipe, as shown.

Bockwich sprays the factory mufflers' rubber isolators with soapy water (for lubricity), then removes the hangers.

He then removes the rear sway bar from its rear mounting brackets using an 18mm socket on the lower nuts and upper bolts, along with a 15mm wrench to hold the lower bolt heads stationary to prevent bolt-spinning (not shown.) Next, he swings the bar out of the way, creating the clearance necessary for the factory mufflers/over-axle pipe assembly to slide out.

The ZR1's factory dual-mode exhaust is vacuum-activated. Bockwich removes both vacuum lines (one on each side) from their butterfly-valve assemblies.

With its over-axle pipe trimmed, the passenger-side muffler assembly slides out freely.

Removing the driver-side muffler assembly requires extra care. Bockwich applies slight pressure to the transmission line so the factory over-axle pipe can slip by unobstructed.

With the stock exhaust fully removed, the ZR1 is ready for the Corsa RSC Track Exhaust System.

Before we get started on the upgrade, let's compare the new preassembled Corsa system (on the left) to the ZR1's factory exhaust. It's easy to see that the Corsa set-with its 321 military-grade stainless steel construction-has better looks and, presumably, longer durability. In fact, it comes with a limited lifetime warranty.

A close-up view of the factory 3-inch axle pipe reveals that it necks down to 2.5 inches as it enters the muffler. The factory tips are also a 2.5-inch internal design.

The Corsa RSC Track Exhaust System (shown unassembled) features a fully-3-inch, straight-path design for the over-axle pipes and muffler inlets/outlets. The tips measure an even larger 4 inches.

Before installing the Corsa system, Bockwich reinstalls the factory crossover-pipe assembly, repeating its removal instructions in reverse order.

He then reinstalls the factory crossover-pipe spring hangers, again by repeating its removal procedure in reverse.

Starting on the passenger side, he loops the Corsa axle pipe over the axle...

...and slides the new pipe's inlet into the factory crossover-pipe outlet.