I've officially decided that I hate exhuasts. Both cars are suffering with problems, and both are causing me headaches.
The SD1 has a strange raspy/metallic knocking noise (hard to describe) when you hit about 3.5krpm. It's been suggested than a slight exhaust blow early on in the system could cause such a noise, so I've been taking it all apart and replacing downpipes and gaskets. The new o/s downpipe went on fine, with all new manifold gaskets/seals. The tried to put the n/s downpipe on and discovered it was about an inch too short. Damn. So put the old one back on (which was ok, just a bit old) and snapped one of the manifold studs. Double damn. So the manifold has been down a machine shop today to get the stud replaced. Hopefully it'll go back together ok when I get chance to get back underneath.
Then there's the Pug. It has near enough the same manifold/downpipe arrangement as my old 205 XS, and that used to piss me off too as it's an arse to get the downpipe/manifold join sealed properly. Dunno why, maybe it's just me. But the 106 hasn't been right since I did the top end overhaul a few weeks ago so decided to have another go at sealing it and also replacing the knackered manifold (the inside of it was broken meaning it was 4-1 rather than 4-2 IYSWIM). This revealed the flimsy downpipe has got a split in it where the metal has fatigued near the flange. Triple damn. So the replacement manifold is now on meaning it's 4-2-1 as it should be, and I've piled in the exhaust putty to try and stop it blowing, which has kinda worked. The cheapest downpipe I can find is £62 delivered and for a little bit more I should be able to find a proper tubular 4-2-1 manifold (which incorporates the whole downpipe and joins to the standard cat), so thats what I'm now after. They look pretty shit hot too - ideal for the motorway commuting car(!)
So there we go, I fecking hate playing with exhuasts. Rant over.