Hello all.

Another weekend --- more grovelling. Look for new 'clonk' that's appeared this week. Simple at any rate -- downpipe tired and confused at entry into first box --- mating flanges between back box and transverse bit turned to lace behind the clamp.
I realised, while grovelling, that virtually all my XM exhaust replacements seem to have centred on these areas, so this time I've gone for some preemptive action. Cut and welded repair plate at downpipe entry into first box and have now added a brace between the pipe and the box seam. I'm sure it's the constant flexing of the engine that does for this part of the system. I don't think the spring loaded ball and socket arrangement they have at the downpipe flange is really flexible enough. I reckon ideally, the system should have a proper support somewhere along the tunnel and then a section of flexible pipe between it and the manifold.
For the rear box flange -- clean and degrease flange areas and apply a couple of coats of high temperature paint, third coat and fit clamp while paint wet, so it fills the scrape marks (hopefully !). Paint around clamp and pipe externally. Time will tell.

Mike.