Nearly all the pre 2014 chassis cars crack at the bottom of the front upright. Had odd later chassis crack at this point.
We have had 2 cars crack at the critical upper rear wishbone mount area - the trouble is that the cracks in this area are so hard to see - they are just small lines like a mini snail trail and both times its been easier to notice as engines had been removed.
We upgrade the whole front end chassis structure and fit the upgraded engine mounts to address the problem. Far more cost effective solution than the MMC new chassis.
The gusset strengthening bracket to the upper chassis section is a major improvement but the chassis will still eventually crack. Don't forget a fair few of the earlier cars were upgraded by dealer/MMC with rectifier mount/gusset plates and welded in A frame at same time as Centa upgrade so although you may think you have a later 'upgraded' chassis fitted, you actually may not
Its quite hard to tell the difference between early and late chassis easily.
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I cannot say how many cars had replacement chassis fitted by Morgan but I can say that they perfected the replacement down to 2 men in under two days. Plenty of practise to get that proficient I would say."You would have better access to the information than me but as MMC allow 4 hours to take an engine out alone, I'd be surprised that they got down to 32 man hours for a complete chassis change which involves body off and remove every component attached to chassis - I could understand 32 man hours maybe for upgrading the existing chassis (which involves body off still ideally) to one with welded in A frame and gusset plates etc. etc.
Oh and regarding the chassis itself - I can park 4 cars next to each other and if you measured mounting points for various suspension items your find that nearly all are different - later cars >2018 etc are far more consistent, perhaps the chassis manufacturer finally invested in a new jig...
