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CF3 flexi leak; options?

Just sorted out my GTV TS rear suspension & thought I'd treat it to a early oil change. Under the front of the car whilst warming the oil and noticed the front flexi blowing on the exhaust. It's a 2002 CF3 with the double pre-cat system. In over words b' expensive to replace.

Searching on here see there are a few old threads suggesting getting the flexi cut out & rewelding a new one in. Is this still the best (low cost) option? Opinions/options please.
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Good luck finding one for sale, either new or second hand. It will be much easier and cheaper to get the flexi cut out and replaced
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I've just been through this last week. Only option was to cut it out and re weld a new one in. Ended up having to take manifold, front pipe and middle pipe off as the bolts were just shearing off so thought the best way was to get it all down grind and drill all bolts. Mark the exhaust either side of the flexi so you have a reference length when welding a new one in. All in all not a terrible job but by no means easy. Job all done cost about 50 quid for a flexi, 4 new gaskets an a few bolts.
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(Post Link) post #4 of 27 Old 25-02-13 Thread Starter
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Cheers, looks like that's the route to go. PITBS but hey! Might look at the clamp on option if enough length on the pipes, looked tight though.
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Just sorted out my GTV TS rear suspension & thought I'd treat it to a early oil change. Under the front of the car whilst warming the oil and noticed the front flexi blowing on the exhaust. It's a 2002 CF3 with the double pre-cat system. In over words b' expensive to replace.

Searching on here see there are a few old threads suggesting getting the flexi cut out & rewelding a new one in. Is this still the best (low cost) option? Opinions/options please.

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(Post Link) post #6 of 27 Old 09-03-13 Thread Starter
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OK, it's a long shot but thought I'd try here before a scrappy lottery. Anyone got a CF3 2.0 L TS twin cat & flex going spare. Would love to go down the Alfaholics stainless replacement route but with free flow cat would double the value of the car.

Thanks Alfatune, shame it was a V6 one.

Just had a quote for 220 to cut & weld in a new flexi, must be cheaper way?

I also see some people retrofit CF2, how much modification for the front lamdas does this need?
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Hello,

Sorry for dragging an old thread up, but I am having the same problem as the OP - the Flexi joint / pipe on my 2002 CF3 Twin Spark is blowing - I have done a search on here and found that the best option seems to be to get the garage to cut the old flexi out, and weld a new one one - the only issue is, where do we get a new flexi for it from? Have done a search through the threads on here, and all of the links to where you can get them from seem to be so old they are dead
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My car's flexi section is not long for this world by the looks of it so would be interested in a solution for this also...
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Any half decent exhaust place should be able to weld a new flexi in from stock. If you can't find one at a garage, find another garage
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I was told last week that the flexi section on the CF3 is difficult to replace with a 'standard' flexi section because one end of the original is oval shaped rather than round. Don't know how tricky that would be to overcome.
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I was told last week that the flexi section on the CF3 is difficult to replace with a 'standard' flexi section because one end of the original is oval shaped rather than round. Don't know how tricky that would be to overcome.
Exactly what I was told as well!

Have found and ordered this on Ebay - didn't initially show up on my searching as I was searching 916 / GTV / CF3 - forgot about the Spider! The engine code listed for it matches mine, so I'll update on how it goes.
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Originally Posted by Sparto 916 View Post
I was told last week that the flexi section on the CF3 is difficult to replace with a 'standard' flexi section because one end of the original is oval shaped rather than round. Don't know how tricky that would be to overcome.
That is true, most flexis are round not oval. That one in the link above looks right though
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Marvelous! Cheers guys!
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I have same problem - looking at the welding option. Have any of you guys finished this job yet and if so how did it go? Any advice appreciated. Alfaworkshop have this - I am guessing this is the part required?


http://www.alfaworkshop.co.uk/images...-565-1-800.jpg
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I have same problem - looking at the welding option. Have any of you guys finished this job yet and if so how did it go? Any advice appreciated. Alfaworkshop have this - I am guessing this is the part required?


http://www.alfaworkshop.co.uk/images...-565-1-800.jpg
Had my flexi that I bought in the link from ebay welded in place yesterday - seems to have done the job ok.
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I have same problem - looking at the welding option. Have any of you guys finished this job yet and if so how did it go? Any advice appreciated. Alfaworkshop have this - I am guessing this is the part required?


http://www.alfaworkshop.co.uk/images...-565-1-800.jpg
I've bought the piece from the ebay link also, although I haven't had it fitted as the section on my car isn't blowing (yet!).

The piece from Alfaworkshop doesn't have the oval shaped ends so won't fit without some 'fettling'.
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Can anyone give me an idea of time to remove the front section of pipe from the car please?

Last edited by iwspider; 25-05-16 at 08:16.
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Can anyone give me an idea of time to remove the front section of pipe from the car please?
I have ordered this part from Ebay for the garage to do next week. Can anyone tell me if I will need to replace gaskets please?
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Didn't realise this thread had been resurrected or would have got back sooner.

Eventually had mine done by Cybox, I work just around the corner from their factory in Bromborough. They cut out and welded in a new flexi part, from memory they only charged 80-90. Have changed the GTV for a V6 Spider so not sure how lasted. They had the capability to get the shape right and part looked good quality. They are also happy to do bespoke stuff, I had some parts made up for work as well (high temperature kiln flu).
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Been reading this thread with interest as mine is blowing slightly and will no doubt get worse with time. Can the welding be done without removing the exhaust? Would I be better off looking for a complete front pipe and doing a straight swap?

Thanks in advance for any advice.
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I ordered the part that others used highlighted in this thread. The garage welded it in without removing downpipe. I also got a price for a second-hand pipe via breakeryard (130)
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Thread Revival.
I have provided the flexi part that I bought from ebay to my local Alfa specialist, but they won't try and fit it because they claim it 'is too long' I have measured the actual flexi section of it and it is just the same size as the original part! To me it just needs the end pipe pieces cut down a bit to fit, but the workshop seem unwilling to tackle it.I have also tried a couple of local exhaust places,but no joy their either.
Any suggestions anyone? Has anyone got a decent second hand cat/flexi section for a CF3?
Getting very frustrated with this situation tbh..
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I was searching through old threads looking for something totally unrelated and found one where someone suggested using a CF2 down pipe and welding in mounts for the two front lambdas. Can't find it again though... Has anyone gone down this route?
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Sparto916 - Obviously plenty of work in your area if the local specialists are happy to turn it away! If you don't have any joy you could always take it to Autolusso in Bedfordshire, they'll be able to sort it out for you. Or if you fancy a drive up to the Lake District then we could weld it in for you, I like a nice exhaust/welding job.

Nelly - yes I've done this. You need to get a 2.0 TS CF2 manifold & downpipe, new exhaust manifold gasket and a pair of lambda bosses. Chop the rear part of the downpipe off just after the 2 into 1, and do the same with your CF3 downpipe. Then you can weld the rear half of the CF3 downpipe to the front half of the CF2 downpipe and it'll be a perfect fit. I usually bolt both bits up, tack the join in place on the car, and then take it off again to get a nice seam weld all the way around.

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Nelly - yes I've done this. You need to get a 2.0 TS CF2 manifold & downpipe, new exhaust manifold gasket and a pair of lambda bosses. Chop the rear part of the downpipe off just after the 2 into 1, and do the same with your CF3 downpipe. Then you can weld the rear half of the CF3 downpipe to the front half of the CF2 downpipe and it'll be a perfect fit. I usually bolt both bits up, tack the join in place on the car, and then take it off again to get a nice seam weld all the way around.
Pud... Cheers, that is looking like an option; will probably depend on what I can and can't get off the car. Is it an option to go for a complete CF2 exhaust and manifold with 2x lambda bosses welded in to save on Cost of welding and having the car off the road for too long?
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