Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 exhaust

My 2015 (may)runs out of warranty at the end of Oct, i see there is a lot of discussion regarding exhausts splitting/failing, i've had a good look at mine and can see no signs of failing, what are the first signs of imminent failure?, i thought i could smell exhaust type fumes yesterday, of course it could have been external and just me being paranoid after hearing about so many failures.

Most of the exhaust failures have been on the Brooklands cars, with their unique exhaust.

There have been a few on early cars however and they crack where the front pipe is welded into the silencer, I have not heard of any cracks post 2013 cars.

MMC strengthened both the weld and the exhaust pipe thickness during 2013 - I know as my 2012 car nearside exhaust snapped off!Exactly where Roger describes.

Thankfully only one mile from home so was able to limp home - making one hell of a racket!!

First signs are a small crack appearing around the threaded portion of mount weld it rapidly sheers without warning around the exhaust pipe - obviously it's under the heat shield so you'll need to remove that and inspect regularly.

Depending on the year you may have a second body mount bracket reducing the chance of fracture-I had a stainless sleeve welded over the mount points on the exhaust providing additional strength.

I was thinking the other day about the Brooklands and others that have actually broken off at the muffler.

What if you took a 1" or 2" long piece of polished stainless tubing the next size up from the pipe O/D and slide it up over the pipe forward, of course after cleaning up and weld left on the pipe or front of the muffler.

Not weld the short piece up to the muffler and then weld the short piece onto the pipe.

In my mind this may be a bit better than just welding the pipe back onto the muffler.

A cracked pipe at the muffler would need to be cut off to do this procedure. But again, I think it would be stronger than the header welded directly to the muffler.

If you were starting from screw, having muffler stubs and pipes sliding over/into each other and using nice stainless clamps would be the best solution in my mind.