Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 Stage 1 Exhaust failure

I took the pipes to my go-to guy for exhaust work. His comment was that the ends of the cans, where the inlet pipes are welded in, are stamped out, and that the stamping process weakens the metal causing the stress cracks. Note that the welds were fine, it was the end of the can that cracked.

As the pipe weld was originally recessed into the end of the muffler can, I suggest that perhaps he could fab a reinforcing "washer" that could be welded to the edge of the can and the inlet pipe. He had a friend laser-cut two stainless disks with the ID of the pipe and the OD of the muffler can. He then re-welded the pipe where the cracks were, and then added the "washer" to the end and welded it to the can and the pipe. Very nice work - looks factory! We'll see how it holds up. He was optimistic...

Here's the re-welded pipes:




Here's a pic of the cracked right-side before repair: