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Discussion Starter #1
Help needed with exhaust back box - I will just explain that althought we are on lockdown i need my corsa to take my mother (who is a key worker (nurse in the nhs) to and from work) otherwise i wouldn't be as keen to fix it.

a few weeks ago i noticed a knocking noise from the rear of my car when going over bumps. i originally thought these were my coil springs as they came up as an adivsory on mot few month ago, I'd already bought new springs i was just waiting for a day off and nice weather, finally managed to get round to replacing them over the weekend. Fitted correctly and went well, however still knocking when going over bumps, so got back under the car had a look round and saw that one of the rubber mountings wasn't there! presuming it had corroded away and fell off (don't know how i didnt notice exhaust was dangling when i was replacing the springs). so at first i just presumed a new rubber holder would cure it, however on closer inspection, part of the pipe that goes onto the back end of the back box had corodded away, and the weld wasn't even there! so was blowing like hell. anyway i knew i had to replace back box so ordered new one from ecp, came yesterday so i took the old back box off, however the part where it has corroded away from the actual back box, part of the pipe has stayed onto the middle section if that makes sense. so the back box is off now, however part of its pipe is stuck on the middle section and won't budge.
For some reason the back box was absoutely full of water and massive clumps of rust, the pipe inside the back box has just disintergrated, so i'm currently driving without a back box until i can get the old pipe off the middle section so that i can put the new back box on if that makes sense. see pictures for more detail. I have tried smacking with a hammer, **** loads of wd40, hammer and chisseling the joint and it will not budge. i don't have access to an oxy torch.
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A clean up with a wire brush so you can see if its welded or not. I've had to grind the slots through on them, then splay the end off the inside piece of pipe.
 

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If it's the same as mine (2006 1.2) the corrosion is horrible!

With mine the rear section slides over the centre pipe (important it's that way around), if so you need to cut that extra part off. Assuming you have a grinder or a decent hacksaw then you should be able to:
1. cut the extra part off where the diameter reduces - you can see the place I mean in your first photo
2. make a second cut from that new end lengthwise along the pipe to one of the slots in the rusty part where it was clamped on - make sure you only cut through the outer pipe, you need the inner one
3. with a chisel/suitably big screwdriver then you can hammer that cut/slot to unwrap the (now cut) piece of outer pipe off the inner one

Then clean up and fit your new back box! slow and painful but should work

Good luck
 

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Discussion Starter #4
Thanks all for the advice. I spent all day yesterday with a hammer and chisel and long flatheads screwdriver, some specialist wd40 and lots of elbow grease and with hours of persuasion it finally came away. See pictures (part that got stuck and new back box). With things like This I don’t think it’s always necessary to grind away as you are running the risk of damaging the middle section which I needed to keep. Took a lot of whacks, plenty of penetrating wd40, chisel and screwdriver
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to get it off as well as around 6 hours work.
 
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