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Aug 24th, 2023
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Joined: Oct 2014
Posts: 5,016 Likes: 3
Charter Member
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Charter Member
Joined: Oct 2014
Posts: 5,016 Likes: 3 |
Hey Bunny!
Congratulations! 1000 postings!
🥂🍾
Hannes
once: Green M3W; 2013
now: Red 4/4 Sport; 2011
and some practical cars for use in real life
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Joined: Mar 2014
Posts: 1,673 Likes: 25
Talk Morgan Enthusiast
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Talk Morgan Enthusiast
Joined: Mar 2014
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Andy
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Joined: Oct 2013
Posts: 1,642
Talk Morgan Enthusiast
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Talk Morgan Enthusiast
Joined: Oct 2013
Posts: 1,642 |
My Portuguese Brooklands exhausts are still going ... no cracks no problems. Must be luck but I guess I deserved it after all my troubles
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Joined: Mar 2014
Posts: 82
Just Getting Started
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Just Getting Started
Joined: Mar 2014
Posts: 82 |
About 1000 kms after my dealer upgraded my M3W to stage 1, after crossing the "Grossglockner Alpine Street" having a lot of fun, at the Hotel in the evening I discovered cracks very similar to your cracks. My dealer did not bother waiting for the factory reaction, he welded both sides - no problem since!
Karl
Life is hard in the mountains
2009 silver +4, 2013 red C4P, 2014 yellow M3W gone to a new owner
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Joined: Jun 2012
Posts: 2,141 Likes: 43
Talk Morgan Expert
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Talk Morgan Expert
Joined: Jun 2012
Posts: 2,141 Likes: 43 |
There seems to be a bad batch of MMC Stage 1 exhausts, several have cracked in the same place as yours, within a few miles. Others have done a lot of miles without problems. I would suggest you try and get Morgan to replace them under warranty as it is a known problem and your mileage is low, they should not fail with such little use. No doubt this will be a long drawn out process, as most warranty claims seem to be. There is a lot to be said for getting non standard parts from sources with a degree of quality control.
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Joined: Jun 2016
Posts: 432
Learner Plates Off!
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OP
Learner Plates Off!
Joined: Jun 2016
Posts: 432 |
About 1000 kms after my dealer upgraded my M3W to stage 1, after crossing the "Grossglockner Alpine Street" having a lot of fun, at the Hotel in the evening I discovered cracks very similar to your cracks. My dealer did not bother waiting for the factory reaction, he welded both sides - no problem since! Karl, did he just weld where the cracks were around the pipes and muffler cans, or did he add any reinforcement gussets?
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Joined: Nov 2011
Posts: 7,061 Likes: 20
Talk Morgan Guru
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Talk Morgan Guru
Joined: Nov 2011
Posts: 7,061 Likes: 20 |
I have a good exhaust guy who has done some nice custom work, so I think I'll take the pipes off and see what he can do with them. I'm not going to wait for Morgan to reply to the dealer, as otherwise I'll miss the entire summer driving season... I've been involved with trying to re-weld and reinforce a Brooklands system, including fitting flexible joints. Even though we really thought that we had done enough to repair the boxes and deal with the inherrent weaknesses, they still cracked in service. The conclusion is that the original materials and construction methods are poor and repairs never hold up. Therefore my advice would be to go to your 'good exhaust guy' and have new boxes fabricated. In your shoes I would also be tempted to have flexi joints incorporated into the new boxes (à la Garage56). Belt and braces etc...Sounds like very good advice
A Morgan Identified Fastidious Owner...
2011 4/4 Bespoke, 1981 Delorean, Auburn Boat Tail
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Joined: Jun 2016
Posts: 432
Learner Plates Off!
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OP
Learner Plates Off!
Joined: Jun 2016
Posts: 432 |
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: ![[Linked Image]](https://www.tm-img.com/images/2020/05/05/20200501_190813.jpg) ![[Linked Image]](https://www.tm-img.com/images/2020/05/05/20200504_151305.jpg) Here's a pic of the cracked right-side before repair: ![[Linked Image]](https://www.tm-img.com/images/2020/04/26/Right-2.jpg)
Last edited by truckin-on; 05/05/20 03:25 AM.
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Joined: Feb 2019
Posts: 3,854 Likes: 2
Talk Morgan Addict
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Talk Morgan Addict
Joined: Feb 2019
Posts: 3,854 Likes: 2 |
That looks good. I believe your guy was correct, the stamping weakens the metal by stretching.
1500 miles is a short time on an exhaust system.
Last edited by LightSpeed; 05/05/20 03:29 AM.
The light at the end of the tunnel is actually a train. 2019 M3W
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Joined: Jan 2015
Posts: 235 Likes: 5
L - Learner Plates On
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L - Learner Plates On
Joined: Jan 2015
Posts: 235 Likes: 5 |
Thanks truckin-on for posting your excellent photos of the exhaust before and after. I too have had a couple of Stage 1 exhausts fail. They were both replaced under warranty although I did have to pay for labour. However have been told that that's it if they go again. No doubt they will go again at some point so your solution and pictures will be a great aid in getting somebody to repair them.
I have had very little in the way of problems with my car over the last 5 years (15000 miles) since purchase hence my lack of posts on TM. Hopefully it will stay that way?!
M3W 'The Mapmog' Built June 2015
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