Check out this welded header.

[Bad Buick]

I did a bunch of performance mods last year before I brought the car out of winter storage. I was so excited....Now this 37000 original Kilometer garage Queen GN was gonna really scream!.....and it ,for about a week Suddenly it seemed sluggish. Seemed to be running rich. Almost seemed like it was chugging if that's a word. Well.....wouldn't you know, I had a crack on my driver's side header . Well I persevered thru the summer. I decided to weld the header this winter. After much reading ,and looking at some of the other board members cracked headers (here I thought I was the only one this had ever happened to) I decided to attack this weld job like I do most projects..."way over the top" I sandblasted the header,then glass beaded it. Then I had the crack tig welded closed. Then I had a small stainless rod welded between the two ports for reinforcement. I then made a plate out of .020 stainless steel to cover the weld, and make it pretty. Finally I had both headers,my crossover, down pipe, and gutted catalytic converter all ceramic coated. I also had three coats of "XMC" thermal coating applied to the insides of all parts. Thanks to Jim C. aka Philly Turbo Six for a great example on how to weld a header. I'd also like to thank Fireball Coatings in Erin Ont. for doing an awesome job of the ceramic coating. Dave

 

[Daniel Jost]

very nice looks great!

 

[gnxtc2]

Looks good on the outside but I would have never coated the inside of the header. If the coating ever flakes off, kiss your turbo good bye. What is the thermal coating rated for?

Billy T.
gnxtc22aol.com

 

[turbofrank]

You should have cut flange support bar. Aids in prevention of cracking again.
Looks good.

 

[TURBOV8R]

Looks great!I'd be afraid to use the damn thing and get it dirty!!:tongue:

 

[Bad Buick]

The thermal coating is rated for 1600 to 2000 degrees, I was told. If it flakes off,and ruins the turbo it will just be a good excuse to get a new bigger turbo....and ceramic coat it,lol Dave

 

[charlief1]

That's purty. You did a nice job.

 

[phillyturbosix]

Looks like the same weld as mine :wink: 3 years going strong with mine and it still looks the same as when I put it on!

 

[3.8L V-8 eater]

Awesome job!!!

 

[Bad Buick]

Thanks Guys,and again Thanks Philly for helping me out by answering my questions when I started the project.

 

[SS_Sean]

Oooooh....that's fred sexy!!

 

[Just a Six??]

Looks good on the outside but I would have never coated the inside of the header. If the coating ever flakes off, kiss your turbo good bye. What is the thermal coating rated for?

Billy T.
gnxtc22aol.com

Not according to Fireball as I just had a set done with the inside in XMC. I questioned Mark a lot about this Same concern. He said that since its a polymer even if it lets loose its not hurting a turbo blade & after doing over 500 turbo headers there has never been 1 complaint. Many asked him as I have so he is aware of the concerns. As for the 1600 degrees thats the outside, the inside can take the 2000 quite easily he claims. Well, I'll know come summer! That will be the proof as I tear it down every year & they will get a Good Inspection! Hoping for the best outcome!

 

[TURBOPOWERED68]

what shop did the work for you?

 

[Bad Buick]

Fireball coatings did all the coatings. They are located in Erin Ontario Canada. Mark Stevenson is the owner 519 833-2628 Dave

 

[TURBOPOWERED68]

what is the expected life of the coating?
what is the expected life of the factory headers with the coating?

 

[turboc87gn]

...

 

[turbobooster]

that looks real good nice work so u say u also welded a small ss rod to the 2 ports to prevent future cracking (which ill b doing when i repair mine) but i dont see it where is it ? maybe its just my eyes playing tricks on me

 

[S2V6RACER]

Mine are also done on the inside. Q.C. Coatings here in MI is the premier coating shop and they have never heard of anybody loosing a turbine wheel because of coating flaking.

 

[Just a Six??]

I did a bunch of performance mods last year before I brought the car out of winter storage. I was so excited....Now this 37000 original Kilometer garage Queen GN was gonna really scream!.....and it ,for about a week Suddenly it seemed sluggish. Seemed to be running rich. Almost seemed like it was chugging if that's a word. Well.....wouldn't you know, I had a crack on my driver's side header . Well I persevered thru the summer. I decided to weld the header this winter. After much reading ,and looking at some of the other board members cracked headers (here I thought I was the only one this had ever happened to) I decided to attack this weld job like I do most projects..."way over the top" I sandblasted the header,then glass beaded it. Then I had the crack tig welded closed. Then I had a small stainless rod welded between the two ports for reinforcement. I then made a plate out of .020 stainless steel to cover the weld, and make it pretty. Finally I had both headers,my crossover, down pipe, and gutted catalytic converter all ceramic coated. I also had three coats of "XMC" thermal coating applied to the insides of all parts. Thanks to Jim C. aka Philly Turbo Six for a great example on how to weld a header. I'd also like to thank Fireball Coatings in Erin Ont. for doing an awesome job of the ceramic coating. Dave

Fireball did one set in Black & one set Ceramic in & out like yours & still good 3 seasons later. VERY MINOR inside bubble type flakes that concerned me. he said throw in some marbles. ball bearings (whatever) & shake a few times to get any (just in case ones) & never had an issue. I threw in some sockets, sand paper, kitchen sink etc & they work & look great still after race days included.

 

[phillyturbosix]

Always cracks me up when these threads from a years past pop back up! :biggrin:

If ceramic coating is done right it will NEVER chip off. Ceramic is done in a totally different process then say power coat. It's dipped in the ceramic coating then baked hard. If anything it will turn back into liquid for a very short brief .0002 of a second and harden back up. Never never powder coat a header. That will flake off in the heat and destroy whatever it goes thru. But if ceramic is done right no issues.

As you guys see this thread is from March 2009 and I think I had mine done on the 87 several years before that and it still looks like new. It will loose it's shine when you put some high heat thru it but you can polish it back up when it goes dull. Ceramic coating is much softer then powder coating. It will polish up like chrome over and over again. I had the entire hooker cat back system ceramic coated on my 87. Looks like it was done yesterday. The best is where all the oil hits the cat back section of the exhaust pipe from those leaky rear main seals over time. I just throw some polish on a rag and it takes the oil stains off and comes right back up like brand new again! Can't beat it.

I must have changed servers since the time I posted on this thread so here are my pics again...

The 87 Weld job...

Before coating...

And AFTER ceramic coating...