Well, I am now part of the broken DC header club. I found a crack going around about half of the bottom side of the flex pipe. I drive my car hard, but still this shouldn't have happenned. DC header for the loss
Btw, I have the very first version of the DC, and got tack welds where the flex pipe meets the flange before installing them.

I first suspected there was a problem a few weeks ago.
Here are the symptoms to look for:
- Low hissing sound even at light throttle. The DC header hisses at WOT, but it shouldn't be hissing if you're not on the gas or pushing the engine. Mine would hiss even if I was barely stepping on the throttle. The sound was very noticeable with the windows down.
- Engine feels like it's struggling at times, especially on the low end with light throttle
- RPMs fluctuate on low end/take offs, and sometimes even drop by 100, 200 at light throttle
- Gas mileage reduced by 3-4 mpg
- Car sounds straight rice, like you have angry bees at all times
- Weird looks from normal people and from ricers with shopping cart wings

This weekend I went in removed the existing a-pipe and replaced it with a custom version created by JTso. This newer version has a larger diamter flex pipe and also a larger diameter where the 2 to 1 collector is. Thanks to Johnny for hooking me up with a very nice custom pipe, shipping it to me fast, and also for putting an extra bung in for my PLX wideband O2 sensor.

Here are some pics. Install went smoothly for me and I'm very happy with the results. Acceleration is very smooth and I have NO hiss now! I've noticed that my a/f ratio is a little leaner. I'm getting 12.5 at full WOT at some points in the RPM range, previously I was closer to 11.5-11.9. This is actually a good thing though, because my SC was running a little rich at some points and this helped to lean everything out, and might even give me some power. I'll have to dyno it sometime when I can get some time off, and also when the weather gets cooler. All my previous ones were done on Comptech's dyno, they're about an hour away from me in the opposite direction of work, so sometimes it's a little hard to get out there. I'll try to get out there soon though.

Pic of the crack. It was pretty deep down the apipe, so it was hard to get a good pic. The red area circled shows where the crack is. I'm going to ship this back to DC for a repair. I should be getting the new production version back as a replacement. I'll be selling the replacement in the black market section later. If you're interested, you can PM me and call dibs though


Side by side comparision pics



Inside of the new larger diameter a-pipe


New A pipe installed, (before I put in my O2 sensors)



I also went in and changed the gasket between the cat and exhaust. The one in my pics was burned up pretty bad. I later found out this was because when the install was done on my cat, they put in a 2.25 diameter gasket, instead of a 2.5. Also, after I took the car for a spin the first time. I heard a very loud rattle anytime I hit 3K RPM or had the ac on. I ended up figuring out that the gasket I bought was too thick. I was able to freely wiggle the cat. I ended up going with no gasket, and tightening it down as hard as good. After that, it was all good. Anyone with the Comptech header and AC rattle, should try wiggling your header/cat and seeing if anything is loose. This is probably not the cause, but doesn't hurt to try.

The gasket that was way too thick:

 

So what headers are you planning on getting?

 

I already have changed to the header I want. I'm now running a DC header with a custom larger diamter a-pipe created by JTso.

 

Time for a dyno.

 

Thats exactly what'll I'll be having done when I inevitably suffer my third flex pipe failure! Good to know I'm now not the only one to have the flex pipe section itself fail.

 

I never knew the DC will crack. Hmmm, this just make the no name stainless steel headers sounds good.

 

yeah DC will crack like a plumbers arse, or a supermodel at a party

 

 

even more reason for me to get the TODA headers!!!!!

now, where is HONDATA with the K-PRO!!!

 

^What're the Toda's, like $1100? Pretty damn pricey.

 

Great job guys! Nice work Johnny! And thanks for the write up K-RocK! Johnny's gonna build me one when i'm ready. <----He just found out Keep us updated on it.

 

more like $1500

 

What was the cost of the custom A pipe?

 

And...I hear ya on the Dyno Johnny. I'll need to try to get one setup soon. I'll have to give the Comptech guys a call.

 

Haha...nice man. You won't be dissappointed with what JTso makes for ya!

...And you should have seen the packaging he sent it in. The a-pipe was so well packed and padded, you would have thought he was shipping a dozen eggs


And: (__________) As for cost, you'll have to talk to JTso. This was a prototype piece and all custom made, so I'm not sure what the price will be. Either way, I'm sure he'll take care of you though.

 

<--- Wonders if Johnny autographs his works of art.

 

^^^It's hidden in the welds and only he knows if it's authentic

 

Wow man JTso just saved DC's ass with this new invention.. Looks good..

 

What was the production date on your header?