Seemed to be having a bit of problem getting my boost up over 10lbs. over the last few weeks. Yesterday, after coming back from a short ride, I noticed an exhaust leak. After seeing several posts about headers cracking, I started looking around there first. There seems to be a few hairline cracks running up and down one pipe right below the flange where the Turbo bolts on, and on the front side, there seems to be a hole in the weld about 1/4 inch by 1/16th inch. Now, can these be fixed not to crack again or is fixing worth it? Whose header doesn't crack? What's a new one worth? This thing did not have a lot of miles on it. Also some of the bolts at the head were loose and one is gone. Should these be run up then cooled down and re-torqued after to make sure they don't come loose?
From the posts here, sounds like this is quite a common problem!!
From the posts here, sounds like this is quite a common problem!!
rerod
Extreme
I am with you on that one. I have a couple cracks on mine also. Last week I tig welded the cracks as good as I could and one trip out and there all back and even bigger.
Climbmax
Expert
Yup one of the cons of front mounts........
Weld her up and get back at it.
CM
Weld her up and get back at it.
CM
snowy1
TY 4 Stroke Guru
like climax said just weld up and ride, I just had to weld mine too. I may try to biuld one this cummer out of heavier material and see how it holds up.
Thanks SuperTurbo, I remember seeing that post, but had forgotten about it. I'll have to check the mounting on mine, it's a powderlite header and seems to me the turbo sits at an angle, so that particular bracket probably wouldn't work unless I replace the header with one from Simons CPR. Then I would probably have a whole bunch of other fitting problems, such as the S pipe, oil return line etc. Wonder if Dave has come up with a bracket for his kit yet, I'll have to check. Meanwhile here's a picture of the problem, is this where they all crack?
Attachments
Man that sucks guys!!
joker2
Extreme
what type of turbo's are you guys running? and what year?
That's where my first CPR broke, Jeff was great to deal with. Talked to him 3 days later had a new and improved version on my sled. Plus he is over 30hrs away. Been pushing the 20lbs most of the season and second header is still in great shape. No cracks yet, knock on wood. The second header came with bracking at the top flange. I also blocked off the open holes in the bulkhead so the cold snow won't hit the hot manifold. The bracket that superturbo makes won't work on the powderlite kit as it sits at a different angle the CPR kit. It is the only down fall of the front design, but I can live with that. As I don't won't under seat heat, lol. 
Heavier gauge metal may help.. Ideally, the sealing weld on the flange should be on the inside of the tube, not the outside. Short weld beads and strengthening ribs can be added to the outside.
