Headers that DON'T crack

Antagon · 08-16-2005, 08:56 PM

My entire exhaust system is full of cracks. I'm replacing the DP and back for sure, but what do I do about the headers and crossover?

I've read dozens of threads about headers here, and heres what i've figured out.

Stock headers crack
ATR headers crack
Postons headers crack

What the ****!? Everyone says the best solution is to get the stock headers welded up, but removing and reinstalling them every couple years looks to be a giant pain in my ass.

The Radius Kid · 08-16-2005, 09:11 PM

Quote:

Originally Posted by Antagon

My entire exhaust system is full of cracks. I'm replacing the DP and back for sure, but what do I do about the headers and crossover?

I've read dozens of threads about headers here, and heres what i've figured out.

Stock headers crack
ATR headers crack
Postons headers crack

What the ****!? Everyone says the best solution is to get the stock headers welded up, but removing and reinstalling them every couple years looks to be a giant pain in my ass.

It's the nature of the beast,lots of heat and backpressure.
The big problem[as I see it] is the lack of an expansion joint in the crossover pipe.
The stainless that they use for TR headers is a lower grade[409].
The ATR's are 304.
Postons [IIRC] are mild steel with ceramic coating.
Heat will make any one of the above listed materials grow.
I would reweld the stock headers[find someone who does a good job].

Antagon · 08-16-2005, 09:24 PM

would it be a smart idea to get the stockers coated as well? i'm afraid they may rot from the inside out that way, but I need to keep my underhood temps as low as possible, so cal weather is brutal!

The Radius Kid · 08-16-2005, 09:35 PM

*IF* I was going to coat them,I would coat them inside and out.

Gnx6 · 08-16-2005, 10:16 PM

When you weld the left bank manifold make sure you put in a gusset or brace between cyls 3 and 5. Sort of like a Solid half moon. Weld that baby in and that will keep it from flexing and cracking.

Antagon · 08-16-2005, 10:22 PM

left bank? Sorry :-/

Would it be worth picking up a new crossover?

The Radius Kid · 08-16-2005, 10:25 PM

If you want to save your original or if it's getting "tired".

CallMeMud · 08-16-2005, 10:29 PM

My ATR's never cracked. I give the nod to them for survival rate.

The Radius Kid · 08-16-2005, 10:32 PM

Quote:

Originally Posted by CallMeMud

My ATR's never cracked. I give the nod to them for survival rate.

I agree,mine didn't either.
They do limit your choices of DP's though.

IfYaGot3Yards · 08-16-2005, 10:47 PM

Quote:

Originally Posted by The Radius Kid

I agree, mine didn't either.

They do limit your choices of DP's though.

Good news: RJC's/Jason's new LC2 DP will be made to fit ATR headers, according a recent post.

Antagon · 08-16-2005, 10:55 PM

ATR's site confused me anyways. I could buy the drivers side header, or both headers with the crossover and up pipe as a package....freakin retarded.

NOCOOLER · 08-16-2005, 11:07 PM

I like welded stockers - forget the gusset, fill the area between 3 & 5 will lots of weld. I've done about 5 this way and they haven't cracked again. The idea is to give it some mass....all of the ones I've seen gusseted have cracked again.

PRSRIZD_V6 · 08-17-2005, 12:02 AM

Bolt them to a junk head and weld very slowly. Despite what some say dont use stainless wire either, regular filler is more ductile and the rate of expansion works in your favor.

my opinion.

87natty · 08-17-2005, 04:01 AM

Does using a power plate reduce the likelyhood of headers cracking?

gordyzx9r · 08-17-2005, 06:04 AM

Quote:

Originally Posted by Antagon

ATR's site confused me anyways. I could buy the drivers side header, or both headers with the crossover and up pipe as a package....freakin retarded.

Their internet catalog is a PITA, try calling them instead.

08-16-2005, 08:56 PM	#1 (permalink)
Antagon Registered User Join Date: Apr 2005 Posts: 514	Headers that DON'T crack My entire exhaust system is full of cracks. I'm replacing the DP and back for sure, but what do I do about the headers and crossover? I've read dozens of threads about headers here, and heres what i've figured out. Stock headers crack ATR headers crack Postons headers crack What the ****!? Everyone says the best solution is to get the stock headers welded up, but removing and reinstalling them every couple years looks to be a giant pain in my ass.

08-16-2005, 09:35 PM	#4 (permalink)
The Radius Kid Registered User Join Date: May 2001 Location: Stoney Creek,Ontario,Canada Posts: 8,983	IF I was going to coat them,I would coat them inside and out. __________________ Politics is the art of glad-handing,passionate bllsht and hidden agendas.

08-16-2005, 10:16 PM	#5 (permalink)
Gnx6 Registered User Join Date: Jun 2003 Posts: 442	When you weld the left bank manifold make sure you put in a gusset or brace between cyls 3 and 5. Sort of like a Solid half moon. Weld that baby in and that will keep it from flexing and cracking. __________________ Scott A. www.turboz24.com Driver

08-16-2005, 10:25 PM	#7 (permalink)
The Radius Kid Registered User Join Date: May 2001 Location: Stoney Creek,Ontario,Canada Posts: 8,983	If you want to save your original or if it's getting "tired". __________________ Politics is the art of glad-handing,passionate bllsht and hidden agendas.

08-16-2005, 11:07 PM	#12 (permalink)
NOCOOLER Growing my Mullet! Join Date: Sep 2000 Location: St. Louis MI Posts: 2,503	I like welded stockers - forget the gusset, fill the area between 3 & 5 will lots of weld. I've done about 5 this way and they haven't cracked again. The idea is to give it some mass....all of the ones I've seen gusseted have cracked again. __________________ - Jeremy 86 T-type - sold......probably was the quickest/fastest peg-leg car. Y2K Pontiac Firebird Formula M6 - Header/ORY/Flowmaster Cat Back - K/N filter 13.2@108 w/1.9 60' on street tires 03 GMC Sierra RCSB 4x4 5.3 CAI - Spal Controlled LS1 EFANS - GMPP Exhaust. Exhaust Clip

08-16-2005, 09:24 PM	#3 (permalink)
Antagon Registered User Join Date: Apr 2005 Posts: 514	would it be a smart idea to get the stockers coated as well? i'm afraid they may rot from the inside out that way, but I need to keep my underhood temps as low as possible, so cal weather is brutal!

08-16-2005, 10:22 PM	#6 (permalink)
Antagon Registered User Join Date: Apr 2005 Posts: 514	left bank? Sorry :-/ Would it be worth picking up a new crossover?

08-16-2005, 10:29 PM	#8 (permalink)
CallMeMud Someone Crown My Ass! Join Date: Jun 2002 Location: North East, MD USA Posts: 7,017	My ATR's never cracked. I give the nod to them for survival rate.

08-16-2005, 10:55 PM	#11 (permalink)
Antagon Registered User Join Date: Apr 2005 Posts: 514	ATR's site confused me anyways. I could buy the drivers side header, or both headers with the crossover and up pipe as a package....freakin retarded.

08-17-2005, 12:02 AM	#13 (permalink)
PRSRIZD_V6 Registered User Join Date: Oct 2000 Location: Flint, MI USA Posts: 1,196	Bolt them to a junk head and weld very slowly. Despite what some say dont use stainless wire either, regular filler is more ductile and the rate of expansion works in your favor. my opinion. __________________ Gavin

08-17-2005, 04:01 AM	#14 (permalink)
87natty Register Boozer Join Date: Mar 2003 Location: South San Diego Posts: 3,681	Does using a power plate reduce the likelyhood of headers cracking? __________________ 'What do you know about surfing? You're from G*ddamn New Jersey!'

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