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[cecil]

Sounds like JJ 's advice rings true. Time for a new exhaust.
 Is it possible the exhaust was damaged by road cushions or was put on/ refitted off kilter putting strain on parts of the exhaust that have since cracked under normal movement. Could the noise be the crack opening shutting and getting bigger with engine movement and thermal expansion?
 Jmariog - I came across that advice as well. I think it (in part at least) depends on how stiff the bodywork is and how the car was jacked up.This could place a twist in the body meaning the engine mounts were still loose even when tightened to the correct settings. Generally the more modern the car the stiffer the body is in order for the suspension to work properly.
 Mr Singh Hopefully you are near the end with all these faults.

[Coverman]

in the case of a kitcar, the exhaust will be chassis mounted rather than body mounted.A kit car with a flexible chassis would these days come under the category of Rubbish.

[mr singh]

its a car... there are always going to be issues. just when you think you've got it sorted, another issue crops up.

the exhaust tail pipes have been bent from day one but its never really bothered me... well it has but not enough to justify me rectifying it. I do suspect that there is a crack of sorts close to the manifold/cat joint.

[Problemchild]

its fab to have a project 

JJ

[mr singh]

today would have been the day that I was taking my forfour to the place I had booked it in for its exhaust fitting... but I had an accident in it on Tuesday  . I ran in to the back of someone (at about 15mph).
I have infirmed my insurance and its currently sat at the bodyshop (of my choice) awaiting an outcome. the owner of the bodyshop seams to think its going to be a write off 

'G' and JJ have seen pictures of it, and having priced the parts i think it need and so far it does seam it could tip the scales either way.

it doesn't look like any of the chassis legs were damaged so if it came to it ill buy it back from the insurance company or get them to pay me to fix it myself, just so it doesn't have that black marker against it.

lucky i bought another forfour which i can use till i find out whats happening with mine.

[CrazyG]

I looked on ebay for what I consider are THE necessary parts...
basically the body panels, as I think you said there was no other
damage.
Ebay is the best source...although none are in white unfortunately.
Cheap too !   I've sent you a couple of links...one not that far from you.

Other parts; if required; can also be found on ebay....so it won't
cost a great deal to fix your car.  Spraying to match might be the most
expensive part if I'm honest...

[mr singh]

apparently the right panel is painted but the centre and bonnet panel require painting , this is the impression I got when I called Mercedes of Leeds.

im (trying) not to jump the gun on buying parts just yet till I hear its fate.

[Scoobysook]

Sorry to hear this. Whatever happens it will get sorted.

[Coverman]

Hope you get it fixed to your satisfaction

[Problemchild]

Cat D (or whatever it’s called now - CAT N) isn’t really a bad mark for a car of this age. Most cars over 10yrs old that have an accident are “written off”

You just have to remember that the term written off isn’t a mechanical statement but a financial statement.

So weigh up all 3 options

1. They repair it all back to factory
2. They give you the money to repair it yourself
3. They write it off and they give you £

Clearly 1 is the best option but most costly
3 isn’t a bad issue as they may pay you £2k and you buy it back for £500

Keep your mind and options open

You are lucky with this car as all the panels can’t be painted off the car which makes the paint guy happy and you are a mechanic with access to tools should be a doddle

As for the headlamp washers - I still think a normal panel will work

JJ

[CrazyG]

...You are lucky with this car as all the panels can’t be painted off the car ...

Think you meant  "nearly all the panels CAN be painted off the car..."

....As for the headlamp washers - I still think a normal panel will work

Every front wing has the markings/'indentations' on the inside so you
can clearly see where to cut out the triangular 'filet' section to fit in
the headlight washers if a wing ever had to be replaced..a great design
feature, as why make 2 types of front wing when 1 can be made with
molded in 'cut lines' that does and will fit all models.

[Problemchild]

What panels can’t?

I can’t think of one

JJ

[cecil]

Try the Tridion! I think that would be hard to get off!
 I hope, given its rarity, that the SB3 can be repaired. Not withstanding the amount of thought and effort you have put into it already

[El Tel]

Pretty much every panel is plastic and can be removed except the bonnet, scuttle (metal) roof and trid, I think.

I spent the last 2-3 years replacing a bunch of panels which were damaged and it’s both cheap and easy to sort. Paint was the biggest expense.

As mentioned, if the legs are straight and sound it’s not hard to change anything else mounted on the front. Mine did bend a bit - millimetres- and I think it is designed as a crumple zone. Check the radiator support - if the frame is out of whack this will also be - it mounts direcly onto the chassis legs and locates the bonnet catch dead center (or off center if there is any distortion in the frame).

Given the price I’ve seen cars go for there wouldn’t it be worth looking for a cheap worn out 454 with the same colour and buy the whole car to scavenge the panels?

[Brabs]

Bonnet (or front lid as Mercedes/smart like to call it) is easily removed and plastic.