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HELP !!- CRACKED HEADER

lf-tp2511lf-tp2511Member
So there I am, pulling the stock starter so I can install the new gear reduction starter, and I see it.

In short, my GTS headers have three cracked tubes, just upstream from the collector. One crack travels to the inside of the four tube juncture, and can probably only be welded by cutting off the outer portion of the tube to gain access.

Of course, I'm headed to Vegas in 10 days, and the Dream Machines show in just 6 days.

Can this poor thing be repaired enough to last through about 1800 miles in the next two weeks?

And if so, will I need to provide the welder a dummy head to hold things in alignment during the welding? Type of welding?

Tips, ideas, and advice needed - ASAP.

Thanks,

Larry

This is the crack that travels down inside the four tubes.

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George PGeorge PAdmin.
Larry,

Drill holes at either end of the crack to prevent the cracks from spreading further. A welder can fix the cracks. Just fix what's visible for now, and see what happens.

Now ask yourself why that header is cracking in the first place, and correct the cause, or it will continue to crack.

About the only hint I can give you, exhaust systems do not like to be rigidly mounted, that's why they are always hung with rubber or cables, never fastened to the chassis with solid mounts.

Another possibility would be b/o motor mounts allowing the motor to flex in the chassis.

Good luck buddy.
v8capriv8capriMember
Yeah, you can see the header is cracking due to it being under pressure or force.
is the flange that bolts to the head one piece ? or 4 pieces that bolt to one cylinnder each. if one piecve cool, if 4 pieces then yes any clevo head will doto bolt them to when welding.
quite often pipes crack due to weight sagging on them.
as for drilling the holes that is great idea even a 1/8" hole each end will do, yes it will leak,but the crack is leaking anyway.
good luck !
O osofastMember
The hole drilling is needed if you want to keep the crack from growing. A quick fix can be to have the holes drilled if you can get to the end of the crack, then have the cracks brazed, this will reach the areas of the crack you may not be able to get the stinger to. Then weld a small piece of steel over the crack just to provide some support. It may not be pretty but it will seal the crack until you can properly address the issue.
Jeff
accobraaccobraMember
The only method to fix this is MIG or TIG .. this will create the least amount of heat and that will make the area around the weld stronger.

From the looks of the crack ..you have some twisting effect going on somewhere probably at the end on the muffler. The stock muffler bracket and the HALL style bracket is a piece of flat steel and causes a twisting effect due the the cantellever ( excuse my spelling ) along with rewelding the header ... add a gusset to the muffler bracket.

Ron
sickcatsickcatMember
Larry,
Sorry to see your troubles,
What I see and here from the other's is correct!
One thing missing is that when metal especialy thin wall tubing is ARC welded it becomes brittle. that is why torch welding is superior!
You don't have the problems with embrittlement.
I see that there was a lot of arc welding in this area and your crack seem's to start there.
When your header is repaired and as long as you have not brazed the repair area, have your welder heat the repair area up with a torch till it is cherry red and cover the area tightly with fiberglass blanket's to allow the metal to draw down, this means it will soften & make it less brittle so it can twist and grow without breaking,

Mark
accobraaccobraMember
CRAZY DAVE ... exactly.

I offer my experience in welding based on numerous welding certifications and field experience in the pipe fitting industry. Gas welding is going to overheat the coating on the header and take the temper out of the metal and the pipe will crack around the new gas weld.

We hit the key points ..good luck.
lf-tp2511lf-tp2511Member
Well, I dropped them off at a shop today. Found another crack about 2" from the head flange.

These puppies are toast. He's going to cut open the tube with the wrap-around crack and weld that up from inside, then weld the thing back together. Miller MIG.

I'll be buying a new set, getting them ceramic-chromed and be good.

In the meantime, if the welds hold for the 2000 miles I'm putting on in the next two weeks, I'll be happy.

Larry
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