Flexi exhaust repair
Sounding like a motor from a demolition derby, this 2007 Ford Ka could be heard before it was seen. There was little doubt as to why the owner had brought the motor to us: the exhaust had fractured and the pipe was now in two halves.
However, the part that had failed was not actually part of the exhaust, but the catalytic convertor. The flexi pipe comes complete with the cat, which not only meant it was going to be expensive, but that the labour to replace it would be higher. The failure was not so much down to corrosion as the continual movement of the pipe as the engine flexed in operation. Fortunately, aftermarket parts manufacturers have a solution: a short flexi repair section that fits into place after cutting off the old flexi pipe and unbolting the flange.
The broken section of pipe was replaced with the repair section, extending the life of the cat.