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[Jukeboxnut]

The exhaust on my faithful hard working 2004 2.2 petrol estate has just started making the most awful rattle on start up. the noise starts to reduce after a minute then stops completely once the engine is up to temperature.
I think it is coming from the cat but the rear box blew its baffle and left a trail of fibreglass up Bury Hill last year.  I stuffed a piece of perforated tube into the tail pipe and it has been fine up now even passing an MOT recently with no problems and perfect emission figures.
Two questions really, are the eternal exhaust systems for sale on ebay any good and is the only option to replace the cat with a second hand part if it is fubared?
Any help or suggestions much appreciated.

[tunnie]

Eternal exhausts last well, just putting another on my 2.2 after last one lasted 5 years 

The sounds you describe suggest a cracked exhaust manifold, common on 2.2's it appears. (Although mine still good at 189k)

Take the cover off and look for cracks.

For cats yes, avoid pattern new like the plague for 2.2, second hand far better.

[Jukeboxnut]

Thanks Tunnie, I will have a look at the manifold carefully later on by the way did not know that the 2.0 exhaust fitted the 2.2 could be a simpler and cheaper job.