Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 Exhaust Flexi Joints

Over the Winter months I don’t use my M3W but I do run it up to temperature about once a month in the garage. I did this the other day and noticed a rattle from the RH exhaust area, this gradually decreased as it warmed up but was still there slightly when hot. It’s from the flexi joint near the cat, I confirmed it from cold, see the video. This is the original exhaust header that has done over 50,000 miles and has a hard time dealing with the wobbly engine and exhaust. I was always amazed that they didn’t break up.

I intend to replace the flexi joints on both sides but found that there are two types that can be hiding under the exterior braid, convoluted or interlocking . Without cutting into it, I imagine we have the interlocking type? Can anyone confirm this before I order some replacements, sometimes called iLok? They are 2” internal diameter and 6” long. Has anyone else had any problems with these flexi joints?

[video]https://www.tm-img.com/images/2025/12/21/Exhaust-Joint-4.mov[/video]

Changed 3 of these joints now - the internal convoluted part splits and the exhaust gasses are then able to come out of the braiding.
Cannot remember where I got the replacements from...

I can recommend P D Gough at Watnall for the repair. They are the outfit who have manufactured replacement Brooklands systems including additional Flexi joints.

Over nearly 14 years, we have had both sides fail with the inner convoluted part leaking... one failed after ~ 3 years (out of warranty & first MOT) and our then dealer fitted an expensive whole new header to fix it. The other one went after ~ 10 years and we got it replaced by an exhaust fabricator near Salisbury. He seemed to have ready access to a joint to do the job.

We seem to have been unlucky with both failing - perhaps this is another "feature" of early cars that was "improved".

I second what Bunny has said about P D Gough at Watnall near Nottingham, they made our replacement Brooklands system, excellent Company to deal with.

I couldn't resist cutting into the flexi joint to see what has happened, they will be replaced anyway. There was only slight exhaust blackening on the underside of the exterior braid but it had fractured all the way round at the rear end, as Stevo666 said. Both sides will be getting replaced with the iLok type flexi, as my exhaust person says they are the more durable type. This one seems to have an interlocking interior pipe inside a convoluted pipe.