Rust already?

[Down2TheC]

In 3 days she's a year off the lot. 11K miles... and already I just noticed rust all over the
exhaust cover/tailpipe thing (on the outside chrome). My '92 Camry pipe covers never rusted
so what gives? Is that normal? Should I be pissed? Maybe it's a sign that
she wants the TRD muffler kit. But I'm not a huge fan of that cover so maybe custom.

[silversurfer220]

My 2004 is doing the same thing. It was built 8/03, and I bought it 10/04 with 100 miles on it. I am going to complain about it the next time it goes into the shop for its "not starting" problem. Kinda ridiculous that an exhaust tip is rusting after 1 year of use.

[Down2TheC]

Heck... mine came off the assembly line like a year and a week ago. Maybe they'll put a new one on if I bitch about it. (That'll last me another year...) Thx for testifying. Nice to know it's not just me.

[PhreakdOut]

In 3 days she's a year off the lot. 11K miles... and already I just noticed rust all over the
exhaust cover/tailpipe thing (on the outside chrome). My '92 Camry pipe covers never rusted
so what gives? Is that normal? Should I be pissed? Maybe it's a sign that
she wants the TRD muffler kit. But I'm not a huge fan of that cover so maybe custom.

Our company supplies Toyota with original equipment exhaust. (But not for the Solara.) Surface rust is common on AISI409 (Center pipes) or AISI439 stainless steel (Muffler body). Really, this is normal. The decorative tip, however, should be made of 304 stainless steel. The higher chromium content should keep it from developing any surface rust.

Just buff it off with some Eagle One product and it should not keep coming back. If it does, send me a message and I talk to Toyota about it.

I'm headed back to Japan on the 13th and I will be meeting with the exhaust development group. They'd love to see pictures of corrosion issues.

[Down2TheC]

Now that's an answer!!! Thanks. I'll do both. I'll get a good picture today and after
the buff I'll post an "after" shot. Hey, maybe you'll get tapped for the Solara tips for the '07.
Thanks!

[PhreakdOut]

My pleasure. I live to embarass our competition.

I'm not a big fan of that style of tip. (Sheet metal rolled and spot welded.)

I suspect the spot weld is the area that the corrosion started.

Thanks for the info. I'll pass along anything you can provide.

[PhreakdOut]

Now that's an answer!!! Thanks. I'll do both. I'll get a good picture today and after
the buff I'll post an "after" shot. Hey, maybe you'll get tapped for the Solara tips for the '07.
Thanks!

Any pics yet? I leave for Japan next Tuesday. I'd like to show this to the Engineer who designed the Solara exhaust.

If he changes the material spec on that part, I'll ask for a few samples.

Let me know when you can post the pics.

Thanks!

[Down2TheC]

Sorry for the delay. I took some Sunday but I didn't like them. I have to check out the macro function on the cam. Closeups were a bit fuzzy. If you want full size images, PM me an email address. If the imagestation size is fine, I'll do another round of pics tonight and post them.

[PhreakdOut]

Down2TheC:

I got the picture via email. I just sent your reponse.

Feel free to post up any part of it you want if you think others might be interested.

Have a good one!

[Down2TheC]

Yeah, I think they'll get a good laugh so I'll post most of your message this weekend. (Need some cut-paste from the PDF) But the mod might push it to the dealer/service gripe forum. Thanks for all your help!

[Down2TheC]

So here's the update... Good news all around. All this time I thought I was just "Stock" when I actually had a mod. Not a good mod though...
Really short version: Phreak is the man!!!
Short version: I'm getting a new muffler and tip!
Long version: Phreak got the this picture:


And quickly (like an hour) responded that it wasn't a product flaw. His response (it's split into four pics so you can read it)



Who knew!? I saw that it was a bit off center but never looked at another stock muffler to see that it wasn't supposed to be tacked on. There's an inner sleeve missing on this one, meaning they even modified the part to tack it on! Lame. But Phreak really knows dem pipes!

The story ends at my dealership. I took these comments to the service/parts manager. It was a bit of a verbal chess game but he decided to order a new muffler and tip for me without admitting that they or anyone they work with would have done this to the car. The claim was that if they damaged it, they'd be covered by insurance and the parts would cost them nothing. So there'd be no reason for anyone there to have this hack job done. (sounds reasonable) At the same time he obviously believed me when I told him that the car had been only in the possesion of myself and his dealership. And I don't have welding gear. After talking to him, my guess is that it happened when they sent it to their sub-contracted shop for the paint protection. But he didn't want to entertain that thought. (in public anyway)

I guess this doesn't help the rest of you out there except as a warning to not let a muffler shop weld dissimilar metals. It basically makes a rust magnet. In this case, my tip became a sacrificial anode and I'm sure my muffler would have rusted through within the five year warrenty since the protection layer had been removed to make the weld. Lesson learned. Second lesson is that when dealing with the dealer, a friendly non-accusatory tone pays off. (and knowledge is power)
Skippy-Double-Wicked-Bad-Evil-Mega-Mad Props to Phreak and SolaraGuy for putting us in touch!!!

P.S. If anyone wants instructions on the "Rusty Tip" mod, I can put a step-by-step in the tutorial section.

[PhreakdOut]

Blush - blush.

I'm very glad it worked out for you. It's nice to see the dealer do the right thing.

Like you said in your last email ... knowledge is power.

Looking forward to that beer at the Elmhurst show in July.

Later!

[Down2TheC]

no prob. I just bought a 3gal Cornelius Keg so I can be the first Solara Mobile Micro Brewery. Beers for the SolaraGuys! (Though beer and cars might not be the smartest combo)

[silversurfer220]

Wow- Mine looks exactly like yours. The digi cam pic that I took shows the same thing. I guess that I'm going to complain when I take it in this week to get my keys re-programmed. Not the way it should be.

[PhreakdOut]

no prob. I just bought a 3gal Cornelius Keg so I can be the first Solara Mobile Micro Brewery. Beers for the SolaraGuys! (Though beer and cars might not be the smartest combo)

We'll keep it to one so we can toast to your victory.