Permanent solution to cracked headers...?

[FastRegalWE2]

I dont know if anyone has tried this, but I think I may have found a way to keep our headers from cracking. The stock or aftermarket crossover must flex, after my stock header cracking (again) in the manner it did this time, on the bottom side of tube 5, obviously it was being pushed on by the x-over. It was a 2 piece design that slid together and was supposed to be clamped in place, I had it welded to make sure it wouldnt leak. This made for a non forgiving system which didnt allow for expansion or twisting motions of the engine. My thought is, to take a pice of the braided exhaust pipe like what is used on FWD cars and replace the bottom straight section of any x-over with it, thus allowing for expansion and twisting and not putting the outward forces onto the headers on either side.
Looking at this unit,

replace the flat lower part that passes by the oil pan with something of this

nature
http://img.alibaba.com/photo/50245293/Automobile_Exhaust_Flexible_Pipe.jpg

it seems like this could eliminate cracking on both stock and aftermarket Poston and such headers.........

Comments?????

 

[soundguy]

over all its a cool idea. From a performance perspective, all those ridges and gaps in the pipe would slow the air flow and increase backpressure. Ideally you want the airflow path as straight and smooth as possible, specially around bends hence mandrel bending. For a stock daily driver this wouldnt be an issue thou and may be a nice cheap mod to prevent future problems.

 

[FastRegalWE2]

I can see that point however, looking inside one of these, they are hardly that rough, and def cleaner than the stock headers, have you looked inside of one of them?

 

[Lee Thompson]

weld

Try welding a gusset between where #3 and #5 runners come together.
This has been working for me for years.

 

[FastRegalWE2]

I have the gussett, its on the top of #5 up by the flange near the head

thanks

 

[Lee Thompson]

.

It needs to be a V to tie # 3 and 5 together. I believe the cracking is the result of heating and cooling. I welded might years ago and it has not cracked since. Have many others also. As far as I know none of them have cracked.

 

[FastRegalWE2]

thats odd, I was just reading of how people have still had problems with them cracking again after welding, mine does tie 3 & 5 together

 

[shanks]

mine just craced just bleow the turbo on the passenger side on the top. So i dont realy think that the crossover pipe was responsible for it.
My driver side cracked a wile ago, i welded it and its been fine since.