A bit exhausting.

Just something for general interest and away from the computer, and no not me physically exhausted, not even after doing this job.

The last few days I had been able to hear a noise at the front of the car that could only be a blow from the exhaust. Having looked under while parked on the street, I was thinking it would be the braided metal flexible joint again, as I replaced that part about three years ago. It is only about a foot or so away from the engine and is a common fault on the Ford Ka for it to break there.
So I couldn't do much in the pouring rain yesterday and left it to look at today.
After setting up the ramps and driving the car up them, I looked underneath now I had room to see properly, and here is the flexible joint.



Although it looks a little worn on closer inspection, it is still OK, so where was the blow coming from?
I then moved the whole pipe and saw there was movement where there shouldn't be, right at the two bolted clamp joint, where the pipe joins the drop down from the catalytic converter.
The whole flange had cracked away from the drop down tube.



So out came the welder and with the pipe propped up at the other end by a small jack, I welded as much round the crack as I can reach.
The photo is after I welded it as the crack itself wouldn't have shown up well in a photo.
However, due to a mounting bracket that at the moment I cannot get undone, as someone else before me has gone and welded over the bolt, that means some small part of the original crack still needs welding.
The catalytic converter is to the right, and goes up to the exhaust manifold on the front of the engine.

Next weekend when I have more time, I can either grind or burn off some of that other persons weld, to be able to remove the bracket and finish the welding where it is needed.

Here are some more shots of the welding I have managed to do, along with the bracket that is in the way for getting round over the top of the bracket.





Although there is still a small amount of the crack unwelded and a small amount of exhaust blows from it, it will at least now carry me through till weekend which being four days as it is a bank holiday, will give me time to finish the whole job completely.
I also realise I must have a slight oil leak from something higher up on the engine, so that can have more attention later too.

 

To repair that problem by replacement would mean a complete new catalytic converter, plus the agro of removing it and replacing gaskets and things to fit the new cat.
Any one bought a new cat recently for any car? In my case a new one would be worth more than the car or nearly, as a quick look shows they are around £120 to £150.
Oh the joys of running old bangers eh?