broken header pipe, is this common
 

I have this support shaft (I believe that is what it is) that connects the turbo waste-gate pipe to one of the exhaust pipes from the cylinder. Yesterday I heard my engine sounding like a 1940s pickup, and looked down and looks like the rod has broken from the header pipe and now I have an exhaust leak. Has anyone seen this and is it possible to weld up this without taking the whole exhaust off.
http://forums.pelicanparts.com/uploa...1525381614.jpg

Looks like a set of GHL headers... I have the same ones, good headers. You should take them off to do a proper job. Pretty hard to TIG up in there...

Well, I drove it to this local muffler place, the guy took 5 mins and $20 and welded a nice bead all around. Sounds like my old 930 again (the tractor sound was embarrassing). So far so good...but still wondering if this is a stress point and it will happen again or not.

It may. The stainless gets brittle over time and continues cracking at the edge of new weld.
If it cracks again it's time for new headers.

+1 it'll probably crack again.

You'd have to remove it and clean it down to good stainless in order for the weld to not be contaminated and weakened.

I had a set like that, and had them repaired a few times.
I got some RarelyL8 headers. problem solved.
Alan

Another solution would be to change Wastegate, one tial46 "for example", it is much lighter than that of the origin and will thus be less binding for your collector of escape. ;-)

JW: I may have some Rarlyl8 headers for sale in a few months so pm if you decide you want an alternative. They will also come with new unused heater boxes.

The right way to fix it if you want it to last. Puts the stress from the WG hanger into the flange instead of the primary.

http://forums.pelicanparts.com/uploa...1526048171.jpg

Grade 304 austenitic stainless is not recommended for "hot service" (between the exhaust manifold and the catalyst). It is prone to corrosion cracking. It is the material that most aftermarket fabricators choose, unfortunately.
OE's use 409 (ferritic stainless) as it is not susceptible to corrosion cracking and the cost is relatively low.
Grade 321 austenitic stainless is also good in hot service but is more expensive. It is used primarily in aircraft.
Headers made from 321 stainless (like those sold by Brian) are worth the investment.
I have a header that Ben from M&K made for me 10 years ago. It's fabricated from 321, has not cracked and probably never will.

Why cheap out on 321, go with Inconel 625.