DC Sports header FAILURE!! WHY?

[19dabeast85]

I've been hearing an exhaust leak under acceleration constantly and started actually smelling the exhaust today so finally decided to take a look, here's what I found:









I can see the welds breaking from a combo of heat and vibration, but it looks like that one part is "peeled" away?? Any experiences with this sorta problem and think it's ok to have an exhaust shop reweld it or should I call this header's time of death?

[ibr_adam09]

i would try to see if a local welder/ muffler shop can weld it for you, it should NOT be expensive at all.

If not, get another Header. IMO i think "DC header's" are crap anyways.

[steelbluesleepR]

i would try to see if a local welder/ muffler shop can weld it for you, it should NOT be expensive at all.

If not, get another Header. IMO i think "DC header's" are crap anyways.

x2, they just make the same header with different flanges for different cars. IMO the only thing that separates them from an ebay header is the quality of the work that put them together. neither of them do any actual engineering into the product.

and yes, a welding shop would definately be able to do it. they'll probably bend it back together, weld it shut, then maybe weld a small plate over it. that's what i would do at least.

[HondaFan81]

Wonder how thick the primary walls are, looks thin. Was that primary tube bent in the past at the 2-1 joint end? Seems like a stress fracture to me, as a result of some bending moment.

You have engine mount/movement issues in the past? Do you have a flex-pipe on the header? Is the header downpipe rear engine block bracket utilized?

The front-to-back motion of our motors can stress the area mentioned, assuming your exhaust manifold flange is properly tightened to head and your header intermediate flange fasteners are tight.

[19dabeast85]

Wonder how thick the primary walls are, looks thin. Was that primary tube bent in the past at the 2-1 joint end? Seems like a stress fracture to me, as a result of some bending moment.

You have engine mount/movement issues in the past? Do you have a flex-pipe on the header? Is the header downpipe rear engine block bracket utilized?

The front-to-back motion of our motors can stress the area mentioned, assuming your exhaust manifold flange is properly tightened to head and your header intermediate flange fasteners are tight.

I'm running all 3 ESP black poly mounts with no front torque mount so the engine doesn't move. Flex pipe is in good condition, however, I have broken two rear block-to-collector brackets and am currently not running anything there. This always worried me, but I couldn't keep them from breaking for some reason....guess I could have hit something putting pressure upward on the collector, breaking that weld...I can see the physics working there to cause this break now.

[F22Turbo702]

It could have cracked because the header was wrapped. They recommend not wrapping them, and they don't warranty cracks on headers that are wrapped.

I've had a flex pipe break before on my DC, but I've never seen one crack like that.

-Kyle

[JoshM]

DC Sports header FAILURE!! WHY?

It's a sign to get your name on the group buy list for Bisi's F22 header.

[19dabeast85]

It's a sign to get your name on the group buy list for Bisi's F22 header.

I know right, trust me I've thought about it, I'd be on there if my budget could at all afford even the half-priced header, just can't at this time.

I'll be changing the oil soon so I'll check the collector for collision signs and see if it's scraped on something. Really the only thing I can remember running over that could have hit the collector happened just a few days ago....I've been hearing the leak for a month almost.

[19dabeast85]

Wonder how thick the primary walls are, looks thin. Was that primary tube bent in the past at the 2-1 joint end? Seems like a stress fracture to me, as a result of some bending moment.

Which picture are you seeing a bend in? Having trouble finding what you're referencing.

EDIT: Here's a couple pictures I found when I first got it (used from reputable member here):

[ebethonda91]

how long have you had those headers for?

[coletrain]

Is it me or does it look like the wrap has deformed the header over time

I can see marks where the header wrap was tightened to the metal.

Is that normal?

[19dabeast85]

how long have you had those headers for?

I purchased it used from a member here in 2007. Installed it November, 2007. Header wrapped it September, 2008.

[ebethonda91]

I purchased it used from a member here in 2007. Installed it November, 2007. Header wrapped it September, 2008.

oh ok cus i read on one of the comments your not suppose to wrap it and i just bought an new one and it came in today and i was reading this i was all man what should i do return it but i need it for smog cus i dont have my origanal one and the one i have now its not smogable lol if thats a word

[dannyd]

DC sports headers................ CRAP!!!!!!!!!!!!!!!!!!!! I have H22A and, same problem with mine, same spot, and mine was cracked all around.

Drummersteve said the same thing, with his old one too.


I agree on the part that they all look the same. the only difference is the flange thingy.

[19dabeast85]

I just took a look under the car and nothing on the exhaust is scraped up except the resonator way back mid-car that always scrapes slightly on larger bumps. The flex pipe&flange is fine, catalytic heat shield in perfect condition, collector-to-oilpan clearance appears to be same as it always has, etc. And here's one more picture I just took that shows a definite long and pretty wide crack: