I really wouldn't worry too much about about returning your exhaust to standard. If you're happy with the way it sounds, simply repair the damaged portion and leave as is. With your known welding skills it should be reasonably straightforward to convert your clamped repair into a welded one.
Rover got themselves into a right tizzy with the exhaust on early cars. The original system generated a resonance under the transmission tunnel that was very audible inside the car and they spent simply ages trying different arrangements. A lot of people get very excitable about exhaust back pressures being critical to correct engine tune and performance. I'd rather say that you might need to adjust the needle type to suit a different exhaust! The principle of providing the freest possible exhaust consistent with an acceptable loudness and note has got to be right and people who tell you otherwise simply don't understand how an IC engine works! Lady C's consumption figures suggest there isn't too much awry, so leave well alone.
Lucky now runs a massive diameter (3" or 3 1/4" - I forget) and a single straight through box alongside the boot. I like the exhaust note, others might find it too loud. But there's absolutely no doubt it gave a significant boost to both performance and fuel consumption. I think far more significant to noise inside the car is how you hang the system. Compliant mounts and plenty of them is the way to go! Remember we only have to fit the system once. Rover were as concerned as to how easy it was to assemble on the line as they were as to the aural result the customer had to live with.
Chris
Rover got themselves into a right tizzy with the exhaust on early cars. The original system generated a resonance under the transmission tunnel that was very audible inside the car and they spent simply ages trying different arrangements. A lot of people get very excitable about exhaust back pressures being critical to correct engine tune and performance. I'd rather say that you might need to adjust the needle type to suit a different exhaust! The principle of providing the freest possible exhaust consistent with an acceptable loudness and note has got to be right and people who tell you otherwise simply don't understand how an IC engine works! Lady C's consumption figures suggest there isn't too much awry, so leave well alone.
Lucky now runs a massive diameter (3" or 3 1/4" - I forget) and a single straight through box alongside the boot. I like the exhaust note, others might find it too loud. But there's absolutely no doubt it gave a significant boost to both performance and fuel consumption. I think far more significant to noise inside the car is how you hang the system. Compliant mounts and plenty of them is the way to go! Remember we only have to fit the system once. Rover were as concerned as to how easy it was to assemble on the line as they were as to the aural result the customer had to live with.
Chris