The specialist: Longlife Stainless Steel Exhausts

By James Mann

| 22 Feb 2023

Classic & Sports Car – The specialist: Longlife Stainless Steel Exhausts

Starting out as a small automotive accessory shop in the Dorset town of Bridport in 1984, Top Gear was an early adopter of online retailing, selling alloy wheels, tyres and, eventually, a range of custom exhausts, under the name Longlife.

Today, Longlife is the UK’s leading supplier and manufacturer of bespoke stainless-steel exhaust systems, with a network of 29 franchised dealers across the British Isles.

“In the past we’ve been heavily involved in the performance and prestige car market,” says director Kevin Page-Smith, “but classic cars are a real growth area for our company.”

Clockwise from top: the exhaust system is cut off over the axle; pipes can be drawn by machine to help form joints specific to the car; pieces are bent to shape

We paid a visit to the Winterbourne Abbas workshop, near Dorchester, run by owner Gary Osborne and experienced fabricator Jarek Szlek.

Joining a larger service-centre garage across the courtyard is a devoted bay for custom-build exhausts.

Gary explains: “A four-post ramp is essential to build and fit a bespoke exhaust system – the car needs to be at its natural ride height, resting on the wheels, to allow for suspension movement.”

Clockwise from top: new pipe is cut; diameter and swage are carefully checked against old pipework; old exhaust pieces are often used to guide correct shapes

Over the years, Longlife has built exhausts to customer specifications for all types of performance and luxury cars, but Gary loves to work on classics.

At the time of our visit, he’s just back from The Classic at Silverstone, supporting a team that enjoys a 15-year relationship with the firm. Now, it’s increasingly part of the day-to-day.

Old exhausts are carefully measured, although systems can also be built from scratch – an appealing option for cars without off-the-shelf availability.

Tungsten Inert Gas welding – here, fixing the fold flange – produces a neater finish than MIG (left); new brackets are made

Jarek, an exhaust fabricator at the firm for 12 years, considers the latest car on the ramp: “This old system is totally wrong for the car, but that’s not uncommon.

“With only one back-box silencer fitted and a number of welded repairs over the years, the mild steel has rusted through.

“As well as external salt and water damage picked up from the road, corrosion builds up inside the system as gases condense and it may not have time to fully dry out if the car is used for short runs, like many classics.”

Pipes are welded, ready to be fitted to this classic Ford Mustang

Gary has invested in a state-of-the-art hydraulic press-bending machine, made by American company Huth Benders, that can bend, swage and expand any pipe from one and a half to three inches in diameter at pressures of up to 1000psi.

When the high-gauge T304 stainless steel used for Longlife exhausts meets a tight bend, another machine, a Mendral bender, is used to manipulate the metal without distortion, allowing for a smooth flow of gas.

Jarek operates the pressure-bender by eye, adjusting the pipe and dies as he works.

Clockwise from top: the new exhaust system is welded in place; rear silencer bracket is welded on; exhaust mounts are adjusted while the car is settled on its suspension to ensure proper clearance

“It’s most important for the run of the exhaust to be as straight as possible,” Jarek says, “but away from brake and fuel lines.

“We often have to create bespoke routing if the old system was poor or if we don’t have one to work from.”

Once the manifold end is clamped, the system starts to take shape, with each section made up and added from front to back.

Gary adds: “All systems should be built in sections so, if there is damage, just that part can be replaced.”

Longlife’s four-post lift gives a clear view of the finished exhaust system

The stainless-steel silencers come in all shapes and sizes to fit any car, and Jarek can expand the pipe on the Huth machine to join the pieces before spot-welding them.

Spot-welded sections of pipe are taken across to the adjacent workshop to be TIG-welded together before being fitted to the car. Jarek points out the superior finish to MIG-welding.

Customers can choose from a wide range of tailpipes on the website or use their original as a pattern, with lifetime guarantees.

Whether it’s here in Dorset, or elsewhere in the UK, the classic side of Longlife’s business is going from strength to strength.

Images: James Mann

The knowledge

Name Longlife Stainless Steel Exhausts
Address (Dorset branch) Esso petrol station, Winterbourne Abbas, Dorset DT2 9LJ
Specialism Custom-built classic and performance exhaust systems
Staff Five
Prices From £500
Tel 01308 301003
Web longlife.co.uk