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Cracked Chad Header


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#1 SSG_CARTER

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Posted 11 August 2019 - 05:49 PM

Inherited thus with the car . Hairline crack at #2 cyl up and around the collector. Braze or reweld?





#2 croquest87

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Posted 11 August 2019 - 06:14 PM

Weld it! That material will be easy to tig/mig just clean it good first. Brazing would work to but nothing like when you melt base material for good  fusion. Perhaps use ss rod/wire

Edited by croquest87, 11 August 2019 - 06:21 PM.


#3 SSG_CARTER

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Posted 11 August 2019 - 08:11 PM

Roger that. Will do. Will update .

#4 ucw458

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Posted 12 August 2019 - 12:13 AM

Brazing shouldn't be used on turbo systems.  Some may disagree with me on that.  But if you are driving hard you can get the exhaust glowing red.  That's about the temp brazing material melts.  So your brazed crack repair may blow open again the first time you get that exhaust really hot.
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#5 SSG_CARTER

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Posted 12 August 2019 - 05:32 PM

Well unfortunately took it to a shop . Hole blowed in it with ss stick. Now I have an expensive paperweight . You get what you pay for.

#6 SSG_CARTER

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Posted 12 August 2019 - 05:32 PM

Thank you I apologize if i sound pissed. I am.

#7 BC_99

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Posted 12 August 2019 - 08:09 PM

Oh no! wt....? Who in the hell would try to stick weld a header??? I am sorry that this happened, however...all might not be lost. Contact Chad and see if he would cut that section out and replace it. I’m sure that it can be saved.... if Chad won’t help you out, Pm me. I am a fabricator/welder. I will take a look at it. Preferably Chad will be willing to fix it, as he would be much more familiar with it, but certainly someone can cut out and splice in a new piece of tubing.

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Steering coupler replacement U-Joints are available here...
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#8 SSG_CARTER

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Posted 12 August 2019 - 09:16 PM

Roger that. I will pm Chad and send pics and details. Thanks for the info, I will keep all posted.

#9 croquest87

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Posted 13 August 2019 - 05:10 AM

Good experienced welder could fix that w no problem. Small piece fabricated and welded in that's all. Good luck.

#10 ucw458

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Posted 13 August 2019 - 12:07 PM

Stick weld,  sounds like you took it to someone who doesn't know what they were doing.  While not impossible to stick weld thin pipes together it's any competent welders last choice to do so.  Stick is reserved for thicker metal.  Mig and tig are the preferred choices.  I would take it to another welding shop.
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#11 SSG_CARTER

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Posted 13 August 2019 - 02:28 PM

Done ✅  reputable shop has it surgery will begin shortly

#12 croquest87

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Posted 13 August 2019 - 02:55 PM

View Postucw458, on 13 August 2019 - 12:07 PM, said:

Stick weld,  sounds like you took it to someone who doesn't know what they were doing.  While not impossible to stick weld thin pipes together it's any competent welders last choice to do so.  Stick is reserved for thicker metal.  Mig and tig are the preferred choices.  I would take it to another welding shop.
Agreed 100%  l only use stick for 1/4 and up structural not so good looking stuff you can paint over. Lol.  It does work well for our OEM cast manifolds w special electrode  drilled end of crack  v grooved heated to 600F  welded at 80 amps  never had one crack after.

Edited by croquest87, 13 August 2019 - 03:04 PM.


#13 SSG_CARTER

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Posted 15 August 2019 - 07:31 PM

She is repaired and good as new. Used a reputable welding company. Lawless Welding Martinsville Va. they repaired the crack along #2 runner cleaned old weld rewelded the collector. It had a crack half way around the base. Excellent work. Thanks all helping me explain what I wanted done. Now back to boost .

#14 croquest87

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Posted 15 August 2019 - 08:26 PM

Glad you fixed it.

#15 BC_99

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Posted 15 August 2019 - 08:33 PM

View PostSSG_CARTER, on 15 August 2019 - 07:31 PM, said:

She is repaired and good as new. Used a reputable welding company. Lawless Welding Martinsville Va. they repaired the crack along #2 runner cleaned old weld rewelded the collector. It had a crack half way around the base. Excellent work. Thanks all helping me explain what I wanted done. Now back to boost .

Pics or it didn’t happen.....

;)

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Steering coupler replacement U-Joints are available here...
http://www.starquest...howtopic=145280

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#16 SSG_CARTER

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Posted 15 August 2019 - 08:53 PM

Someone pm me a cell number and I will provide after pics.

#17 SSG_CARTER

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Posted 15 August 2019 - 10:00 PM

Pictures are in my Gallery under Chad header repair.

#18 03CL55AMG

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Posted 05 September 2019 - 04:01 PM

how long did you have that header on the car....and how often do you drive it.
Forged motor, weisco pistons ,3" exhaust, garret 60 cold/ 70 hot turbo, bosch 1000cc injectors. meth kit. chads intake and header. holly EFI stand alone. *DM intercooler. grimspeed boost controler. stock cam.

#19 SSG_CARTER

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Posted 06 September 2019 - 09:53 PM

I imagine 10 years or so from previous owner info. It is as good as new now.  I drive this car about everyday if i can. Not far but driven daily to to diagnose and learn the mpi tuning with this Haltech E6K.

#20 Tim_C.

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Posted 01 December 2019 - 07:57 AM

That's actually pretty good for a header. Daily driving and learning to tune can increase exhaust temps considerably. The best turbo headers made for any car will crack eventually.
'87TSi .510Roller Cam, JE Forged, TS Rings & plateau honed walls, lightened rods, race prepped crank, mains line honed, balanced, 17C, 3"EX, 2"HardPipes, AlFly, rrfpr, 88trans, 3.90's w/posi plate mods, polyBushings, STSprings, KYBStruts, Camber Plates, CustomAlternator
Traded for new set of tires for my wife's Buick: '87 TSI Gold that needs just about all steering and suspension parts replaced, injectors, a new transmission, clutch, and various electrical gremlins. New owner is a mechanic who is already driving it. I couldn't stand letting it sit any more!
'86 ESiR - OEM Roller Cam, Wiseco Forged 8:1 Pistons, Chad's equal length header, TEP T3/T4 turbo, ACT HD clutch, Fidanza Fly, custom 3" exhaust, 3 core oversized radiator, O-ringed block, AJUSA metal shim head gasket, Dawes Device boost controller
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'96 Mitsu Mirage w/rebuilt head. Gets 35+MPG.
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