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MG MGA - Stainless Exhaust Leak

I have a new Falcon stainless steel exhaust system on my Coupe. The system comes in three pieces, which are clamped together with stainless steel exhaust clamps. I've noticed an apparent leak between the first and second section, evidenced by carbon/soot deposits on the pipe at the joint. I'll try tightening the clamp, but was wondering if there is a better solution. Can stainless steel exhaust pipes be welded together to eliminate any leaks?

Regards,
M.D.
'57 Coupe
M. D.

Yes stainless can be welded or brazed using the correct welding rod/wire.
John H

As a temporary fix, you can put a piece of MUFFLER TAPE at both end of the exhaust pipe sections and then put the clamp on, and tighten it. The tape will fill any small spaces and close the leak while not being visible (under the clamp).
Gordon Harrison

Funny, I've called a few muffler shops and they claim that they are not able to weld stainless steel. Is this some kind of specialty welding technique?

Regards,
M.D.
'57 Coupe
M. D.

MD,
Stainless most certainly can be MIG welded. I welded a stainless oxygen sensor bung into my Falcon system with ease. I'll be welding the rest to get rid of the same exact problem. Let me know if I can help.
BOL,
Doug
D Sjostrom

Just get a tube of orange Permatex (hi-temp gasket sealer). Try to get the joint apart, goop the stuff on the male end and slide it back together. Lasts forever and you don't have to fool around with a welder.
John Vallely
John Vallely

Most muffler shops can expand the inner pipe to give a tighter fit. They use a roller tool.
Art

Not only can stainless be welded, it can be welded to mild steel or to aluminized steel. You need to find a better muffler shop!

To prevent leaking, the only good way to mount an exhaust system is to weld all seams. Stainless as a material is susceptible to more exapnsion and contraction from heat and cool than other materials used on exhaust systems. Mild steel has fewer problems but rusts easily.

Aluminuzed steel is what is used on modern exhaust systems and has the benefits of both of the other materials. It is a thcker wall, does not expand and contract so much and will not rust. Notice that on most newer cars, no matter how old and nasty the car gets the exhaust still looks fresh! I had a piece of aluminized steel welded into the Falcon system on my MGB GT when I removed the front resonator. Went in fine and no problems since.
Steve Simmons

When you find the right shop, make sure that when you ask for the system to be welded, they weld the entire muffler pipe. I got one welded several years ago, and didn't look at the job they did until later. All they did was tack weld on both sides of the pipe and clamp the pipes together. Needless to say, I wasn't happy.
Mike Parker

If you look at the bracket where the 2 meet, you will see that the bracket is too far back. Just break the weld a move it forward this will let the front pipe & muffler go together to close the gap. I had the same problem, this is how I made my fix. Yes a Mig welder will do the job, with gas not flux wire.
C.C. Jones

The Falcon system must have changed because the one I bought 20 years ago (and am just installing!) is only in two pieces with the join just before the box. The bracket for the central hanger was too far back and I've had to remove it. I've just been looking in my welder instructions for rewelding the bracket and it says for stainless welds use 75% Argon 25% CO2 - do not use pure CO2. Also use stainless steel wire. In addition to this it says 'for welds that require corrosion strength use 98% Argon 2% CO2. Mike
m.j. moore

I have a Falcon exhaust too. I'm on the second after the original was replaced under guarantee (after 13 years) when the baffles failed.

It's only a two piece one as well.

I slipped some exhaust sealant onto the joint before I slid the two halves together (I thought all installers did this), and the joint is gas tight after about 20k on the new rear section
dominic clancy

M D

Have you simply tried loosening the clamp and pushing the two sections together yet? Mine did that, exposing the slit in the pipe end. Pushed then together with an exhaust type sealant, tighten clamp - job done (6 or 7 years ago)

Pete
Pete Tipping

Thanks for all your comments and advice. It sounds like Falcon has gone from two-piece to three-piece, at least on this side of the pond (probably for shipping reasons). My leak is at the first joint, just beneath the driver's door, not at the muffler. The muffler joint looks fine, and seems to be more clamp-friendly in its design.

I'll try calling a few more muffler shops, or maybe a motorcyle shop to see if I can find someone experienced enough to weld stainless steel. I think welding the problem joint will give me more peace of mind. If I can't find anyone that can weld it, then I'll try sealing it myself.

Regards,
M.D.
'57 Coupe
M. D.

This thread was discussed between 21/04/2006 and 24/04/2006

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