Hey Marc. Yea my headers were cracked... they didn't look too bad, sort of spiderwebby, but they were fairly bad. I was only building 13psi of boost with a good chip, and 10psi w/the stock chip. Didn't have an adjustable wastegate tho. I got Terry's stock headers when I bought his motor, they were also cracked, not as bad as mine though.
Nick knows a guy who's good with welding, and he welded Nick's headers, so I gave Nick all 4 of my headers and got them back welded, for a damn cheap price too
Craig was saying that with the fixed up headers it will be a lot quiter under the hood and run a lot better. So I'm lookin forward to it (engine going in soon!)
Since I pulled my engine, getting the headers off was nothing, but I'm told they're not too bad to take off with the engine in the car. Each header's held on by 6 bolts (3 on top, 3 on the bottom). No gasket even. If your drivers side is cracked, you should be able to pull that one pretty easily (unbolt the crossover pipe first).
Like crazygn said, they are definitely worth it. You probably don't want to take it to a shop though (unless u can find a nice and honest one who knows what they're doing). I asked minute muffler about mine and they said it would be about a days labour! That's not something I'd want to pay for
Craig could definitely help you out if you're interested.
Oh yea man, I forgot, I said I could get your car on my tlink or gtech. I'd love to do that for ya. TLink'll give ya some good info about turning and whatnot, and of course the gtech'll give you (with pretty good accuracy) your 1/4 mile time & mph. So yea, if you're ever interested, try me at home at 269-7363
see ya!
Dave