Is it possible to repair this header, or am I looking at a replacement?
Posted by NYCBYB@reddit | projectcar | View on Reddit | 31 comments
It’s an easy job to swap out, but sourcing a new header will suck. I suspect it will need to be custom fabricated.
Threedawg@reddit
Any idea why it broke?
NYCBYB@reddit (OP)
I was at the race track driving pretty hard.
Threedawg@reddit
Huh, maybe engine mounts?
NYCBYB@reddit (OP)
Maybe. They’re pretty stiff. It happened when I was flat out on the straight. Maybe the 4-5 shift jostled it? I was passing a 70’s Boss 302 that was super loud. Maybe it was some kind of crazy resonance. I’ve probably got about 4K hard miles on it, so could just be a bad weld too.
RBuilds916@reddit
With that 1/2" gap, I think the header must have been under stress just sitting still. Maybe it warped when it was being welded or some residual stress developed from the exhaust heat or it got bent. Whoever fixes it just needs to slice the tube, line it up and reweld.
devilpants@reddit
It looks like the pipe is a half inch or so “off” after it broke so maybe something way putting a lot of tension on the header. Think about adding a flex pipe or better mounts if the motor torques a bunch.
grumpyligaments@reddit
this. my old exhaust on my spyder didnt have one and would break at the end of the header all the time. stock exhaust has flex. no issue.
jarhead1801@reddit
The weld itself held—the pipe is what failed. It can be repaired by welding, but unless the root cause of the failure is identified, it's likely to happen again. The pipe has shifted and will need to be heated and realigned before re-welding.
Did exhuast work for meny years.
Dseries_EK@reddit
Do you have a flexible pipe in your exhaust system? While I don't, I'm constantly thinking about if it could lead to something like your issue.
Data_shade@reddit
Danger to manifold
RacerX400@reddit
Yes it could be rewelded. But it shows that the pipe is under stress if it’s pulled that far away. I would be concerned that it would happen again simply because of the initial process in fabrication.
Special-Catch-8947@reddit
Use this to learn how to weld, if you send it to Satan, you needed one anyway.
Beansoverbitches@reddit
Haha pretty cool reaction that must’ve been figuring out what you did “holy shit bro I sent her so hard it blew the weld off the header”
TheDarkChunk7@reddit
If thats cast iron, do NOT weld! However, if thats stainless I would say go for it. Although a new header isn't really too much money. Sometimes better safe than sorry.
KaOsGypsy@reddit
If it's cast iron, get a welder that knows what they're doing, I weld cast occasionally, it's not difficult, there are just special procedures you need to follow.
TheDarkChunk7@reddit
Yeah I never implied that you can't weld cast iron. Just usually more of a job for a seasoned welder. From what I understand is, that it's a pain in the ass and usually easier to buy new.
Roadkill215@reddit
It’s not cast, but you certainly can weld cast. It’s just a specific process and filler
Wogger23@reddit
Seriously did you look at the picture? It’s a tube header, and you can see it broke at the weld. What part of this picture looks like a cast iron manifold?
TheDarkChunk7@reddit
Bro, I get up at 4am everyday for work. Lol. Which is when I responded. Obviously not awake enough to see clearly. Geeze.
Imaginary-Trust-7934@reddit
I remember seeing some of that guy's k swap MR2 motor mounts (toyonda or however he spells it) on some Facebook post years ago, at least at that particular time the welds on the parts he was trying to advertise with looked horrendous.
Imaginary-Trust-7934@reddit
Looks like he has since paid a better fabricator or gotten better himself over the passed few years, but I remember when I saw their posts around 2020ish some of that shit was looking seriously woof-y for something you're actually trying to sell/use as advertising for your parts company and not just some shit you did for yourself or your buddies
Mitt102486@reddit
In confused. If you race cars, you would know that you can weld that. Is this post asking for help or bragging?
Roadkill215@reddit
The weld didn’t fail on this, the tube did from fatigue. Part of the tube will still be In the manifold. I would guess that the tube wasn’t bent quite correctly with how it moved over after breaking or something is causing a lot of load on the manifold. fatigue breaks can happen, especially at that point due to the different expansion rates and the flange being stronger resisting flex but the major shift in tube position should not. I’d have the others thoroughly inspected while it’s off.
On higher end quality headers, you’ll see the inside of the tube completely welded with stainless to the flange and the outside with silicon bronze. The silicon bronze provides support yet is soft enough to allow flex so this doesn’t happen.
Leicageek@reddit
Not an ideal header design but common. Thin tubing on a thick plate with no bracing. It should weld up ok. Make sure when there’s a place for the header to be supported instead of making it take the weight of the rest of your exhaust. In other words make sure the turbo isn’t just hanging of the manifold and that the exhaust is not hanging either. If that makes sense. I’m falling asleep
4x4Welder@reddit
I'd fix it, but probably also put a brace on all of them. A square wrapped around about half the pipe an inch or so from the flange, then a 1/2x1/8 piece of bar from that square to the flange. It'll help keep the tube welds from getting stressed.
Natedoggsk8@reddit
Get it tig welded but bring it to the welder as clean as possible about be 2 inches from the weld or an inch at least.
FalseRelease4@reddit
And if you dont know how to clean it then dont, very easy to make it worse
hotdonut@reddit
Any decent welder can fix that.
FabOctopus@reddit
Toyonda? Mr2 k swap?
NYCBYB@reddit (OP)
Yes. An MR2 Spyder with a K24.
vorsprung46@reddit
For sure. Take it off And bring it to the welder.