Stock Tubular Header Cracking

[ScoobySteve]

Like almost everyone on here with the tubular exhaust headers, mine developed leaks.

I recently had the head off and it was a great opportunity to remove the headers, and take a look at where they were leaking. The #2,#3 y-pipe was fine but the #1,#4 was in sorry shape. On one the branches the pipe was cracked all the way around the joint.

My mechanic designs custom headers for high-end cars and was taking a look at the design. The factory pieces have some triangular bracing that's nearly seam-welded. In his opinion, the bracing is what actually causes the cracking due to asymmetric thermal expansion. We actually removed the braces and rewelded the whole Y area.

Hopefully this will have better longevity.