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This last weekend I tracked down a new vibration that had started about 2 weeks ago.
The right header had completely broken right behind the collector.
In retrospect I believe this has been a long time in development. Probably started cracking back to our trip up to Alaska and all those rough roads in the Yukon and the Haul Road up to the arctic circle.
I should have caught it earlier, but it happened so gradually I did not notice the exhaust had changed so drastically until it was repaired.
This is on the right side, right after the cross-over pipe out of the collector.
It broke right past the factory weld. Even after it was completely broken the hose clamp that holds the heat shield onto the pipes was keeping it perfectly lined up.
I am pretty sure I could have gotten it replaced under warranty. But figured it would be easier to repair than to remove the cat out of the new header.
So we covered up all the paint and wires and welded it back together.
The pipe HD used in these headers is some of the worst material we have ever seen. After welding it up, we checked for any leaks. Then we formed a 3" x 1" piece of mild steel and welded it to the backside across the joint to give it some extra strength.
Have been riding it for a couple of days since the repair. No leaks and much different sound than I had gradually become accustomed to.
At some point I will be putting some aftermarket headers on, but right now we wanted to get it back right with the stock headers for some dyno testing of new parts in a few weeks.
Kevin
The right header had completely broken right behind the collector.
In retrospect I believe this has been a long time in development. Probably started cracking back to our trip up to Alaska and all those rough roads in the Yukon and the Haul Road up to the arctic circle.
I should have caught it earlier, but it happened so gradually I did not notice the exhaust had changed so drastically until it was repaired.
This is on the right side, right after the cross-over pipe out of the collector.
It broke right past the factory weld. Even after it was completely broken the hose clamp that holds the heat shield onto the pipes was keeping it perfectly lined up.
I am pretty sure I could have gotten it replaced under warranty. But figured it would be easier to repair than to remove the cat out of the new header.
So we covered up all the paint and wires and welded it back together.
The pipe HD used in these headers is some of the worst material we have ever seen. After welding it up, we checked for any leaks. Then we formed a 3" x 1" piece of mild steel and welded it to the backside across the joint to give it some extra strength.
Have been riding it for a couple of days since the repair. No leaks and much different sound than I had gradually become accustomed to.
At some point I will be putting some aftermarket headers on, but right now we wanted to get it back right with the stock headers for some dyno testing of new parts in a few weeks.
Kevin
