Pure Adrenaline

iTrader: (2)

So a few weeks ago, I started hearing loud ticking noises from the engine bay. Upon inspection, I realized I had a leak on the rear exhaust manifold. Why, oh why, did it have to be on the rear bank header!? It is such a pain in the ass to get in there.

After taking out the header, I realized I had massive leaks on my hands. The center pipe and the right side pipe were cracked so badly, they were halfway off the flange. I wish I could've taken pictures, but I didn't have access to a camera at the time.

So after calling 5 different places in the phonebook, my friend and I finally found a place that will weld small stuff. Hauled ass over there, only to find out it will take a day to do it. After pleading and begging, the guy said he will get it done in an hour. Gave him extra cash for taking care of it fast, and the welds looked beautiful.

So I came back and put it back on... left for home and I realized I still had a leak. :wtf: Took everything apart again (ugh, such a pain in the ass), realigned the downpipe with the header, but nope. At this point, I started getting mad.

Then yesterday, I took everything off again, and the gasket had carbon deposits on both outer exhaust ports. Didn't I tighten the nuts down enough on the ends? Or could it be that.... oh, no.. I took a straight edge to the flange, and yep, sure enough, it was WARPED. The guy must've dipped it in water right away or something. We're talking about 1-2mm off on each end.

Took a metal disc grinder to it for a couple of hours and just went at it. Finally, we sanded it down close enough, so I put it back on and tightened the HELL out of the end nuts.

And finally, the leak was gone.

Well, at least for now.

Might not sound like a big problem, but imagine trying to figure out where the leak is coming from... a warped flange off by few millimeters would be the last thing you would look at.


Cliff's notes --

Big leaks, pipes were cracked so bad, I could see through them, got it welded, but he warped the flange, had to grind it down, finally fixed leak.

CL Platano

all I can say is damn..I would of just thrown the stocks on and bought new ones

PenancE

damn that blows....what a way to use a weekend....its holiday this weekend too for yall..

blk2001tlon19s

glad the leaks are gone now!

TLsu

Good work none the less...most people wouldn't have figured it out.

Sorry to hear that happen. Comptech FTW.

Excelerate

iTrader: (1)

That sucks; it's so annoying to do the same job a few times over although you do end up getting better at it everytime. Some ppl say to double up the gaskets but I have never done that and I've been advised by other exhaust guys to not to do it. I've learned my lesson on these cheap parts and refuse to sell them locally or online b/c it's just not worth the hassle. Glad to see you got everything worked out, hopefully for at least a few years.

I know everyone always knocks Comptech b/c of the price but there are never any issues like this and this is what I suspect will happen with all these cheap replacements: OBX, SS Autochrome (XS Power; ebay headers), Alpha Werks, etc.

subinf

i wonder why the welder did that. were you waiting for the header? normally when i weld something for a customer i let it sit for a little while, or at least ask them if they want me to dunk it if they seem to be in a hurry. anyway, glad you got it taken care of

Pure Adrenaline

iTrader: (2)

Nope, he told me to come back in an hour, so I left and came back.

I think the reason he did it was because he didn't know any better. They do lots of big industrial stuff usually, not small automotive stuff where few millimeters make a big difference. In fact, they were working on a semi-trailer oil tanker while I was there. I mean, he was cool about it, so I don't think he was out to screw me over.

Pure Adrenaline

iTrader: (2)

Mmm, I don't think it's a good idea to double up on the gaskets. That's like double bagging it, and that just isn't safe.

Phesto

hey pure, were your headers wrapped? did this lead to your problem?..........reason I ask,when I had a str8 pipe put in on my megans to cut the reasonance.My exhaust guy said I should remove my header wrap also before my megans crack...........I didnt believe him because they have been wrapped for like 2,000 miles already with no problem.But now I am a little worried


BTW: good job on the repair.......your very patient,I would have smashed something

MikePA

The guy might not have dunked the header, the heat from the welding could have warped the flange.

Edward'TLS

The piping cracks at the flange are common occurence for stainless steel headers, especially so if the pipings have to be forced to fit properly. Ceramic-coated mild steel headers are more forgiving to stress-related crackings.

Pure Adrenaline

iTrader: (2)

Nope, no header wrap. And I've never heard of header wrap warping the headers, but I suppose it's possible. If the exhaust gas is hot enough and the wrap is preventing the heat from dissipating on the surface of the headers, then it could lead to warping... but that's just me guessing. I wouldn't worry about it.



MikePA -- Yeah, that's possible, too. Either way, he wasn't careful enough. 1-2mm on each end is a big warp.

PenancE

u contact obx at all and tell em what happened?

aaronnn

i doubt obx woulda done anything.. these headers are old. and i dont think obx even distrubutes them anymore. the only way to find obx for our TL's now is ebay or used.

i bought mine from a guy on the forums.. i put about 50,000+ miles on it now. umm about a year and a half. i still have no problems with it. i dont get why so many people complain about their obx's..

CleanCL

iTrader: (4)

could have just bought used comptechs. the price of the obx + cost to repair + your time and aggravation, could have been avoided.

fsttyms1

do a little search on them and you will see nothing but problems

kpierson

You wanted it done immediately. I've learned never to tell a welder you need something done sooner then they tell you they can provide it. Welding is not something you want to cut corners or rush on.

Whenever you heat metal up its going to warp, thats just a part of it. He should have allowed the part to cool down completely between passes to minimize the warpage. But, 1 hour doesn't provide near enough time to weld and let cool between passes!

At least you saved the headers and got them back on.

ryebreadisme

iTrader: (1)

the comptechs are wat too expensive. We're very lucky DC came along and put out the Ceramic coated header that they did for our cars

Pure Adrenaline

iTrader: (2)

I don't know shit about welding.

I had to get it done right away, because I had to leave town the next morning. I saw a way to get it done fast, but I couldn't foresee the problems it created. I've learned my lesson. But at the same time, I think the guy could've done better, like informing me of the possible consequences. But I guess it's water under the bridge now. The fact of the matter is that the cracks are fixed, and the flange is straight enough now to prevent leaks. That's all that matters.

fsttyms1

i would have used superglue to fix the problem!

MrAlex

I have to fix my megan headers too.. they have not 1 years and they all cracked.. i think is because my motor mounts are all busted .. (im waiting for new one for about 1 1/2 month now ..) i can see 2 big crack on the front one , i dont know about the back.. but they make a crappy sound i have a new downpipe now that i ordered from my seller, and i dont know if they will send me another set under warranty ? but ill cost me another 150-200$ to install do you have an easy way to fix it for cheap ?

TL_PJ

Wow what a pain in the a**. Atleast you got it fixed, sometimes you gotta do it yourself!

Pure Adrenaline

iTrader: (2)

D'oh!! So that's what I've been doing wrong all these years.

NSXNEXT

iTrader: (2)

Money well spent. My Comptechs are over 6 years old and still look great.

fsttyms1

Yep. Super glue and Duck tape fix every thing!

Pure Adrenaline

iTrader: (2)

You forgot zip ties.

fsttyms1

how'd i forget them lil things

SatinSilverTypS

iTrader: (1)

yeah man, i had most of my girlfriend's old ford tempo held together with those things and it's still holding together at 110,000 miles with the new owner.

SSTS