Well team, this is how it panned out. Considered the option of welding the pipe to the box (care of the thread on exhausts) so I called in at a local 'side street' mechanic this morning. He felt it was too corroded at the business end to do a decent job. It was a Honda pipe so I think it must have been the original. Almost 65,000 on the clock so a poor performance really. My hunch is that the previous owners only used it for shopping and local trips @ 5,000 per annum. As always in these cases, it seems it rusted out rather than wore out. Too much sitting around. Pity about the crack. The box section appeared to be rock solid on the outside. Option two. Replace the part. My operative matched my best quote with a Klarius (same group as Timax apparently) including a three year warranty. Checked up about Bosal which are well regarded in the trade but it seems the problem is getting hold of them at the right price and volume etc. Apparently they have now retreated back to Belgium of all places. I thought the Sprouts only did chocolate and rules. I considered stainless steel but given the age and 'gofer' status of the car I decided to go short term. Tony did a nice job. No hammers allowed on my insistence and punishable by inverted suspension from the ramp at max height. I don't think he would have resorted to a Kwik Fitter Fit anyway. Seemed far too sensible. Heat treated it, removed the rusty bits and bobs handled the Cat with kid gloves and refitted with a proper kit and no nasty cement etc. So now back to, well almost silence but for the bearings which were temporarily drowned out by the cacophony. Scared the hell out of the neighbours. Sounded more like a Chieftain Tank starting up. Amazing amount of noise for such a dinky little engine. Thanks all for the feedback etc. Really helpful as always.
