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Wales
by Joske Vermeule, September 1
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Jun 14th, 2026
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Joined: Nov 2011
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OP
Talk Morgan Guru
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New Cars with cracks in the Headlight cowls...
The attached photos were taken of the headlight cowls on a brand new 2013 +4 after the car was parked in the sun for an hour.
Both headlight cowls developed a split in the same place along the join to the body big enough to slide a credit card into. When we examined the car a few day later in the cool of the evening the crack had substantially closed. Morgan claim it is to do with heat and humidity – sounds reasonable.
There have been 3 new Morgans (+4, and Roadster) in Australia so far with the same problem.
No doubt heat is a major contributor but if this can happen on a mild autumn morning in Sydney, I hate to think what may happen when we get some real heat.
As the northern hemisphere moves into summer (hopefully soon) this may be a real watch point for all owners of new Morgan cars.
Has anyone had any experience with this?
Last edited by OZ 4/4; 20/06/13 10:11 AM.
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Joined: Feb 2011
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Member of the Inner Circle
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Member of the Inner Circle
Joined: Feb 2011
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Replace your lovely car for a new one John? Nooooooo!!
Jays
Former Morgan owner. Gone but hopefully not forgotten!
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Joined: Apr 2012
Posts: 5,013 Likes: 32
Charter Member
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Charter Member
Joined: Apr 2012
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'Morgan claim it's to do with the heat'? And?
And this shouldn't have happened and we'll put it right? What are they doing about it?
We've all had cars in high temperatures - this doesn't happen.
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Joined: Nov 2011
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Talk Morgan Guru
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Talk Morgan Guru
Joined: Nov 2011
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The car has now returned after 5 weeks off the road in the repair shop while Morgan decided what to do.  It was fixed under warranty so the owners credit card should have no further participation  Thankfully the repairer stood his ground and insisted on a proper welded repair. Seems the root cause was a poor welding effort during construction in the first place and the glue was just smeared along the outside join. No news on the other two problem cars but will hear something soon I suspect. Wonder how many other new Morgans suffer the same curse?  As Charles said quite deliberately I think at the Talk Mog visit whilst ignoring the issue of failing windscreens. The cars are "hand assembelled" not you will note hand built.
Frankly as I head for retirement I wonder if I would exchange my car for a new one. I am sceptical seeing all these faults that the marketing dream (& incidentally always my dream) of a bespoke car that was loving hand built to an acceptabel quality can be delivered.
A Morgan Identified Fastidious Owner...
2011 4/4 Bespoke, 1981 Delorean, Auburn Boat Tail
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Joined: Jul 2007
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Salty Sea Dog Member of the Inner Circle
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Salty Sea Dog Member of the Inner Circle
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If I remember correctly? (getting harder nowadays!  ) the headlamp pods are welded onto the wings at Superform...
Graham (G4FUJ)
Sold L44FOR 4/4 Giallo Fly
'11 MINI Countryman Cooper D All4
'90 LR 90 SW
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Green & Grown Up Talk Morgan Addict
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Green & Grown Up Talk Morgan Addict
Joined: May 2009
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If I remember correctly? (getting harder nowadays! ) the headlamp pods are welded onto the wings at Superform... Just going to ask that question? They have not started using that 'Super Glue' now, have they?  It must be soul destroying to have this happen!
Last edited by Frank 4x4; 21/06/13 06:42 AM.
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Scruffy Oik Member of the Inner Circle
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Scruffy Oik Member of the Inner Circle
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One of the big risks of outsourcing production of sub-components. If it is down to poor assembly at Superform, MMC may be able to recoup the cost of remediation, but the reputational risk is going to be hard for them to deal with...
Tim H.
1986 4/4 VVTi Sport, 2002 LR Defender, 2022 Mini Cooper SE
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Member of the Inner Circle
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If I remember correctly? (getting harder nowadays! ) the headlamp pods are welded onto the wings at Superform... They are. Its not a continuous weld and then MMC fill in the join at the factory. Any poor weld...which I'd be surprised to see, should have been picked up then. Head light pod Head light pod 2
Jays
Former Morgan owner. Gone but hopefully not forgotten!
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Joined: Jul 2007
Posts: 28,901 Likes: 352
Salty Sea Dog Member of the Inner Circle
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Salty Sea Dog Member of the Inner Circle
Joined: Jul 2007
Posts: 28,901 Likes: 352 |
Ahh, thanks.
So, there is the possiblilty for different expansion rates...
Not a pretty sight!
Graham (G4FUJ)
Sold L44FOR 4/4 Giallo Fly
'11 MINI Countryman Cooper D All4
'90 LR 90 SW
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Joined: Nov 2011
Posts: 7,342 Likes: 49
Talk Morgan Guru
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Talk Morgan Guru
Joined: Nov 2011
Posts: 7,342 Likes: 49 |
Thanks for the photos Jays. Interesting that the cracks appeared on both cowls in almost the same place It will be curious to see if the other affected cars were the same. We only know of 3 at the moment but there may be more. Word will get around so we should know more soon. Seems like a Morgan quality control problem so fingers crossed for new Morgan owners as it gets hotter. 
A Morgan Identified Fastidious Owner...
2011 4/4 Bespoke, 1981 Delorean, Auburn Boat Tail
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Joined: Jan 2012
Posts: 14,976 Likes: 2
Member of the Inner Circle
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Member of the Inner Circle
Joined: Jan 2012
Posts: 14,976 Likes: 2 |
If I remember correctly? (getting harder nowadays! ) the headlamp pods are welded onto the wings at Superform... They are. Its not a continuous weld and then MMC fill in the join at the factory. Any poor weld...which I'd be surprised to see, should have been picked up then. Head light pod Head light pod 2 Thanks Jays. Very interesting.
Richard
1976 4/4 4 Seater
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