I accidentally cut a hole in the flex pipe when I was cutting the bolts out of the flange. The clearance was terrible and I cut with too much haste.

my flex pipe is in terrible condition anyway. Can I get a new one welded on? I can’t really afford a full new manifold & cat 

Probably. My V6 Mondeo needed a full exhaust but Ford no longer supply the flex portion of the exhaust so I went to a local exhaust specialist for a full stainless exhaust, before and after the cat including welding up a new flex section, that cost no more tham a Ford exhaust would have. They were a franchise for Longlife Exhaust and had a couple of interesting rally and race cars there when mine was in that they were making custom exhausts for.

 

2 hours ago, CursedBones said:

I accidentally cut a hole in the flex pipe when I was cutting the bolts out of the flange. The clearance was terrible and I cut with too much haste.

my flex pipe is in terrible condition anyway. Can I get a new one welded on? I can’t really afford a full new manifold & cat 

yes it can be cut off and a new one welded on but you need to take the whole thing off the manifold apparently so it can be done off the car..my flexi was blowing on my zetec s 1.6ti and thats what the garage did.

3 hours ago, OvEr_KiLL said:

yes it can be cut off and a new one welded on but you need to take the whole thing off the manifold apparently so it can be done off the car..my flexi was blowing on my zetec s 1.6ti and thats what the garage did.

Perfect! I have removed it. I hope somewhere is open tomorrow with it being a new bank holiday 

As above, it's perfectly doable, but, you've got to take the exhaust manifold/cat off to do it.  

On 5/8/2023 at 8:51 PM, mickywrx said:

As above, it's perfectly doable, but, you've got to take the exhaust manifold/cat off to do it.  

I took the manifold assembly to a guy that is 5* recommended on google with hundreds of ratings and he told me that he will weld a new flexi and flange on but it needs to be on the car to get it positioned perfectly. 

I told him that the subframe is in the way but he just said to trust him as he does it for a living.

He wanted £150 and I managed to find an unused official fomoco one on eBay for £220 with shipping so I’ve decided to go for that as it’s n absolute steal.

I am worried about it being fake but everything looks identical to mine and it is stamped up with serial codes etc