Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 A coil bracket failure!

Thanks for pointing out, rolsmith

Checked mine, is fine...to me it seems very robust MK 1,5 chassis , sep. 2013


touching ash,
Smaug

2 Radiators, 1 radiator repair, 3 front wing brackets, 3 rear shock absorber brackets, 2 alternators, 1 fuel pump and 1 ignition switch. The factory responded well on warranty repairs but obtaining parts for DIY repairs left a lot to be desired.

Having read about bobbin failures on the M3W, I think the problems I had with leaking radiators could have been avoided if a better quality bobbin had been used for the upper mounting point.

It’s been a while since I’ve read anything about broken coil brackets – but that doesn’t mean that it’s not happening any more!


My M3W is a mid 2012 model so especially prone to the problem.

It’s a bit of a PITA to repair because the area is tightly packed with wiring harness and hydraulics. Therefore, you need to take precautions so as not to melt anything when re-welding. I covered up the front of the car with protective sheeting and used plenty of wet toweling & wet fiberglass mat immediately around and underneath the weld area. Then I welded in short bursts to keep the temperatures under control. I ended up with a weld along the full length of the bracket which should do the trick long term.

From some time in 2013 (I think) the welding of the bracket to the chassis cross-member was improved so as to avoid this problem, but if you have an earlier model, just keep an eye on the bracket welds for signs of cracking.

Hi Andy,
That is what my bracket looked like, just tacked in place for the most part. I went thru much the same procedure, making sure I did not melt any vital bits. My M3W was built in July of ‘13.
I now have a 2015 frame and it seems to be more robust in a number of areas.

I have tried to not comment on the early model welding issues because as a Certified Welding Inspector there are possible professional ramifications for my comments, but enough is enough. The welding problems on the early models were caused by poor joint fitment before welding and welding technique designed to produce the absolute fastest welding production with little regard for metallurgical considerations of the solidifying weld, shrinkage stresses, grain structure, etc.
This is obvious from the pictures taken of the failures they have had on this forum. There may have been some design issues with some of the bracket designs but the welds that broke were not good welds.

You can't beat someone who knows what they are talking about.

I have heard a number of people express similar views , you are not alone. The problem is there doesnt seem to be anything that can be done to remedy the situation for early owners in a proactive way.

Replacing the chassis is one way!

What does a chassis cost?

The replacement chassis will of course have been welded together by the same people as the one you want to replace...Catch 22 anyone?

I will absolutely bow to Knucklefreak's knowledge but will take a guess that the welding is flux core (MIG) a process often carried out by "semi-skilled welders". Set up and prepared just right it works beautifully and quickly, not quite right or dubious weld prep and like all weld processes it can be pretty damn poor. You have to hope that when it isn't working just right the welders have the knowledge and ability to recognise what is happening and can adjust things back into the zone.