Thanks for the info guys! I think you're both right; probably the best thing will be to hack the flange off and weld a new one on there. The cats seem to be fine, with the exception of the heat shields starting to fall off. The reason I mentioned the flange crack as a "common problem" was because that's what I was told. I was lucky enough to run into a rover mechanic that used to work at the local dealership, when I mentioned the leak which I thought was coming from the flange not sealing tight, he told me about the cracking that he'd seen many times before, and actually told me EXACTLY where it cracks. Sure enough, when I got in there and looked very closely from the inside, there it was!
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Drewfuss
'63 Series IIa: parabolic spring packs, 33x9.50 mud tires, Kodiak Heater, Fairey OD (SOLD)
'95 Jeep YJ: 8"lift (SOA), 35x12.50BFG Muds, Ford 8.8 rear w/detriot & disc brakes, 4.88 gears, warn8000i, daylighters......
'99 Jeep XJ: 3" Skyjacker, 31x10.50 MTR (SOLD)
'95 NAS D90 Wagon, front skid plate, brushguard, Hellas, 285/75 R16 Dunlop Mud Rovers, custom guages & dash
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