After having no problems on my 2000 mile road trip over the last couple of weeks, on start up yesterday I could hear a bit of an exhaust blow.

On first investigation I thought that this stud had perhaps worked its way out, it certainly isn't in properly.



But once the engine was on I was not sure how I missed this hole.



I will try to clean up the surrounding area and try to weld on a patch, or look for a second hand cat if that fails.

The CAT looks like a real pain to replace, there seems to be no access from the engine bay.

 

Tonight I used a flap disc to get to solid bright steel before trying to weld on a patch. The end result is a hole to big for my poor welding abilities.

I'll drop in to Davy the welder on Friday to see if he can tackle it.

The upside is that the car now sounds like a real big American muscle car.

 

Davy the welder says no problem, booked in 9am on Monday!

 

Was there impact involved to cause the initial small hole and crack or just rusted through?

Graham

 

No impact, it was just rusted through, the bigger area was paper thin.

 

Good grief!

I'll slide under mine for a check this weekend.

Graham

 

My mind must be in the gutter since when I saw the title of the thread I was expecting the worst

Anyway this would appear to be a good excuse to jettison the stock cats and install something supposedly more high-performance?

Doug

 

20 mins and £20 later the job was done.

 

It looks like a blind cobblers thumb, but no-ones going to see it and if it works it was a good deal at £20.