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Old 04-12-2016, 08:12 PM   #1
xxBrun0xx
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Openflash Header Broken Welds

Been running my openflash header for about 6 months. All was well until about 2 weeks ago when I noticed a faint ticking noise at low rpm, high load. It's steadily gotten worse since then, and after replacing the header to op gasket (no luck), then trying to use copper RTV (no luck), I found this. I've been a huge supporter of openflash for a long time and expected better, which is why I started with gaskets. Has this happened to anyone else? Is there any kind of warranty on these?

@Shiv@Openflash
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Old 04-12-2016, 08:14 PM   #2
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One year warranty. Right there on the website.
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Old 04-12-2016, 08:31 PM   #3
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Yeah there was another post a little while ago. Seems to only be a few though.
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Old 04-12-2016, 08:44 PM   #4
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Originally Posted by xxBrun0xx View Post
I've been a huge supporter of openflash for a long time and expected better, which is why I started with gaskets. Has this happened to anyone else?
What is the rest of your exhaust like?

As is the case with failures of this type, it's because it's the weakest part of the overall exhaust system. If you have any aftermarket exhausts or components, or if your OE hangers have excessive movement, it can contribute to the weld failing.

-alex
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Old 04-12-2016, 08:54 PM   #5
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What is the rest of your exhaust like?

As is the case with failures of this type, it's because it's the weakest part of the overall exhaust system. If you have any aftermarket exhausts or components, or if your OE hangers have excessive movement, it can contribute to the weld failing.

-alex
I've got a TRD catback and everything else is stock.
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Old 04-12-2016, 08:58 PM   #6
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Quote:
Originally Posted by xxBrun0xx View Post
Been running my openflash header for about 6 months. All was well until about 2 weeks ago when I noticed a faint ticking noise at low rpm, high load. It's steadily gotten worse since then, and after replacing the header to op gasket (no luck), then trying to use copper RTV (no luck), I found this. I've been a huge supporter of openflash for a long time and expected better, which is why I started with gaskets. Has this happened to anyone else? Is there any kind of warranty on these?

@Shiv@Openflash
Here's mine. About 10k miles.

Name:  uploadfromtaptalk1460509090481.jpg
Views: 3543
Size:  53.3 KBName:  uploadfromtaptalk1460509103055.jpg
Views: 3482
Size:  53.6 KB

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Old 04-12-2016, 09:11 PM   #7
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I've got a TRD catback and everything else is stock.
How many miles on the car? How are your stock exhaust hangers?
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Old 04-12-2016, 09:19 PM   #8
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Here's mine. About 10k miles.

Attachment 135337Attachment 135338

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Damn! Is this a common problem with headers that don't have slip or flex sections?

-Josh
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Old 04-12-2016, 10:33 PM   #9
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Originally Posted by Yoshoobaroo View Post
Damn! Is this a common problem with headers that don't have slip or flex sections?

-Josh
No,

That crack is from all those fish eyes. Google "tig welding fisheye" for an explanation as its not my place to talk about others welding practices however i don't want miss information to be spread as to why something would crack. FWIW there's pictures on this forum of what's regarded as a super high end header that's full of them too.
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Old 04-12-2016, 11:16 PM   #10
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Originally Posted by Yoshoobaroo View Post
Damn! Is this a common problem with headers that don't have slip or flex sections?

-Josh
Interesting point.......that wouldn't surprise me ...... but, I fer sure.


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Old 04-13-2016, 05:27 AM   #11
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Quote:
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How many miles on the car? How are your stock exhaust hangers?
43k on the car. Exhaust hangers aren't broken. Do these go bad?
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Old 04-13-2016, 09:24 AM   #12
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Quote:
Originally Posted by JDLAutoDesign View Post
No,

That crack is from all those fish eyes. Google "tig welding fisheye" for an explanation as its not my place to talk about others welding practices however i don't want miss information to be spread as to why something would crack. FWIW there's pictures on this forum of what's regarded as a super high end header that's full of them too.
That sure looks like a nice spot to grow a stress crack from. That's unfortunate. OP, does yours also show fisheyes? Hope you get it resolved.

-Josh
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Old 04-13-2016, 10:19 AM   #13
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Originally Posted by JDLAutoDesign View Post
No,

That crack is from all those fish eyes. Google "tig welding fisheye" for an explanation as its not my place to talk about others welding practices however i don't want miss information to be spread as to why something would crack. FWIW there's pictures on this forum of what's regarded as a super high end header that's full of them too.
Well don't just tell us... show us!
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Old 04-14-2016, 12:09 AM   #14
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My OFH cracked in the same spot. Mine was number 0020 from the first batch. Openflash sent me a warranty replacement. I sold it to another FR-S owner and he has been running with it for almost 2 years. I picked up the JDL UEL with flex joints.
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