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There's no way that crack can be tig welded all the way around on the car because there's not enough room to get at all of the crack while they are on the car.
Also like has been mentioned you want to make sure there's no particles of metal left behind inside the headers because they will destroy the exhaust turbine wheel in the turbo.
Take the headers off and have them welded by someone that knows what they are doing and it sounds like your buddy may not the guy to do it. He could probably tack weld part of the crack while they are on the car but thats a big risk because the turbo could be destroyed by possible metal slag particles left behind inside the header tube.
I didn't know B&B would fix them for free. That may be for the original owner only if thats true and if all checks out then you have to box them up and ship them at your expense anyway.
They have to be removed to be repaired and welded correctly.
My B&B headers cracked in the same places around 7or 8 years ago. I removed them, cleaned up the metal around the crack with a wire brush on a die grinder and then took them to a local guy to have the crack and broken support bracket tig welded.
He charged me $50 and the headers have held up fine since then.
Good luck with it.
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