Automobile or motorbike exhaust systems are intended to eliminate exhaust gases and vapours from the engine cylinders, cool them down afterwards and, of great importance, reduce noise and toxic emissions into the environment.

Under which circumstances a silencer repair may be required

The necessity of repairing this vehicle component is usually linked to the malfunction of one of its elements:

  • the muffler can, which most often fails as a result of mechanical damage or rust;
  • exhaust manifold. This element is frequently affected by high temperatures and a clogged or melted catalytic converter, which prevents exhaust gases from leaving the system;
  • the catalytic converter. The malfunction may occur over time with the honeycomb melting or sooting, resulting in the necessity of repairing the silencer;
  • corrugation. This component is prone to burn due to catalytic converter malfunctions and rupture due to impact;
  • resonator. This component no longer functions properly as a result of damage, overheating or rust.

Detecting a hole in your silencer is not a difficult task. The resulting noise is deafening and can be highly unpleasant and annoying, as well as causing problems for the car’s engine. The burning through of welds while your car remains in service necessitates an urgent repair to restore all the broken joints.

There are a variety of ways to repair a punctured exhaust pipe. Our service centre provides professional silencer repair as well as welding.

When repairing the exhaust system, our mechanics use the appropriate equipment and consumables that allow us to perform the entire scope of the repair of the exhaust system at a high quality level.

Our car service center provides a list of services that include:

1.Diagnosis of the exhaust system.

2.Repair of exhaust silencer, its welding.

3.Replacement of the exhaust pipe, resonator, intake pipe.

The most frequent cause of damage is the centre and the rear part – the resonator and the silencer, much less common is the intake pipe. If one or more components fail or cannot be repaired, it is replaced either in parts or as a complete unit.

4.Replacement and repair of the system exhaust manifold.

The main symptoms pointing to a leaky exhaust manifold or exhaust manifold gasket are a loud engine noise and an exhaust smell in the vehicle compartment. Once this occurs, the exhaust manifold is removed and the cause of the leak is identified. The problem may be either the gasket or a crack in the manifold itself. Such a fault can be rectified by replacing the gasket, replacing the manifold or repairing the manifold by welding it together.

5.Replacement of gaskets, clamps, rubbers, repair kits.

6.Diagnosing the catalytic converter malfunction. Carrying out catalytic converter replacement.

The major causes of catalytic converter failure are:

  • Ageing of the part, due to which there is a loss of so-called “afterburning” properties. This is the most common cause of catalytic converter failure, as the catalytic converter has a lifetime of correct functioning of about 100,000 km.
  • physical damage, e.g. due to an impact. It occurs fairly frequently, due to the very fragile ceramic material inside the catalytic converter.
  • Clogging of the catalytic converter honeycomb. This fault generally occurs higher in diesel-engine vehicles. The causes are improper mixture formation, oil ingress into the exhaust system and loss of traction. The result is a loss of traction and engine output.

The catalytic converter’s primary function in the exhaust system is to reduce the emission of harmful substances from the combustion of fuel into the environment. This is its primary function from an environmental point of view.

7.Installation of a flame damper. Installation of the catalytic converter.

A flame damper may be installed in place of the catalytic converter on some vehicles, but in this case a catalytic converter cheater must be installed.

A flame damper can only be mounted if the vehicle is not marked with an ecological class (Euro……) on the vehicle specification sheet. Should this not be the case, a flame damper may be mounted in place of the catalytic converter and a catalytic converter bump on the lower lambda sensor may be installed.

8.Removal and replacement of the diesel particulate filter (for diesel cars).

9.Diagnose and replace the lambda sensor.

10.Exhaust system tuning.

11.Possibility to manufacture custom-made silencers.

How to repair a vehicle’s exhaust pipe

The first thing to do is to disassemble the part and analyse the damage and the general condition of the material from which the silencer is made.

So, the first thing to do, regardless of the technique we will use to repair the silencer opening, is of course to remove all the rust and dirt covering it, which will simplify subsequent operations and make them much more efficient.

To degrease and remove rust, a soak in a special solution for a few hours may be applied, followed by a thorough scrubbing with a steel brush.

This is necessary to remove any roughness and ridges. Afterwards, we rinse the silencer to remove any remaining dirt and dry it thoroughly to prevent rust reappearing.

Welding is undoubtedly the best in terms of appearance and quality of sealing, it is mandatory to be proficient in this technique in order to do the work properly. For this reason, we recommend contacting our service centre where our experts will carry out the welding work in a professional manner.

Main steps of an exhaust system repair, silencer welding

The excellent quality of any silencer welding procedure is the result of thorough fulfillment of all stages of the procedure. The diagnosis of the technical condition of the exhaust silencer helps to determine the list of necessary repairs. Parts of the exhaust silencer that are significantly damaged due to rust are removed before the repair work begins. Cleaning and degreasing the surfaces positively affects the resulting resistance of the weld.

Metal brushes and abrasives are used to remove corrosion and stubborn dirt. The parts to be welded are previously tack welded together. In most cases when professional silencer welding is performed, a rod is used that is placed on the joint line. The semi-automatic welding of an exhaust system produces a welded joint that is resistant to high temperatures, vibrations and any external conditions that could negatively affect the state of the exhaust silencer.

The main advantages of semi-automatic welding of an exhaust pipe

Welding with a semi-automatic welding machine can be used when the exhaust silencer is damaged in numerous ways. The use of semi-automatic welding ensures excellent quality and long life of the welds.

The advantages of this type of repair are as follows:

  • smooth welds without thermal deformations are obtained;
  • mechanical strength of the connection;
  • sealing and durability of welds is guaranteed;
  • subsequent long service life of the restored component.

Furthermore, exhaust pipe repair tubes, flanges and expansion joints are used for exhaust pipe repair. These are used to considerably extend the life of the old exhaust silencer.

A detailed diagnosis of the vehicle’s exhaust system by a specialist before any repairs are carried out guarantees the highest precision and quality, carried out on the specific features of the vehicle being serviced.

Our service is dedicated to restoring your vehicle’s exhaust system to full working order.

We can offer welding services of the highest quality, capable of covering any thickness and any type of weld metal. We have been working professionally and precisely for many years, focusing on the efficient performance of the work in order to reduce costs and time as much as possible.

Our specialists guarantee work on time, provide a guarantee on all types of work and offer reasonable prices for all repairs.