Borla Header Lawn Mower
 

Good day everyone,

I recently installed a new Borla UEL header and am experiencing a bit of a weird issue. When I start the car, it sounds like a lawn mower. As soon as I put the car in gear and drive away, the noise is much quieter and slowly goes away as the car heats up.

I should mention that I reused the gaskets when installing the headers and the only exhaust modification I have, are headers.

Thanks,
Gilbert

I would suspect it to be the gaskets. Most gaskets are meant to be used once as they crush/deform during installation. Based on what you're describing, it sounds like you have a leak at the gaskets and once the car is warmed up, the gasket/pipes expand and fill in the gaps. I would install new gaskets.

I have my money on exhaust leak at the gaskets where they meet the head.

Scott

What's weird as I drive 3 feet, stop and the noise is gone. If I sitting still and rev the engine, the noise remains at idle.

Sorry you didn't get to see my post before you installed yours: http://www.ft86club.com/forums/showp...&postcount=296

I think that you have a leak from re-using gaskets and the flanges on the header may be warped like many others. A bunch of us are getting them replaced under warranty with Borla right now due to warped flanges that cause leaks... :(

Odd. Could be due to heat expansion is more exaggerated with headers.

First thing I would do is eliminate the easy. Check around your gaskets for black scoring which would indicate a leak. It would be best if you could get under the car with the engine idling. (SAFELY!)

Once you have ruled out exhaust leaks, then move on to more possibilities such as your exhaust sensors.

Scott

Forgot about this! :happy0180:

Scott

I am waiting on a replacement header from borla as well.
Cold start sounds like a tractor, once warmed up it is not as bad due to the metal expanding and sealing slightly better.

Our car does the same thing. The high idle when starting the car produces some extra noise, and once the car idles down it is fine. There is no leak. We have tested this with the car in the air searching for leaks on start up.

Most likely the thin walls of the header passing the noise along. The stock system has thicker walls plus shielding to keep things quiet. The cat also helps with noise.

^what speed factory said. Took my car back to @Pure Automotive just to make sure there was no leak and everything checked out fine. Even with stock exhaust car was louder when cold start until it drops down below 1k. I just don't move it until it's warmed up. catless=more stinky anyway! FTW

Awesome avatar lol

When I pulled mine off I had carbon/blowby on one of the gaskets, the tractor sound was most definately a leak in my case and the flange was most decidedly warped.

I know the header is a little louder on cold start due to the thin walls, but many of us have actual warped flanges that do not seal properly as the tick/leak sound was also there when warmed up, just not as loud. It sounds like someone is shaking a tin can full of thumbtacks

Damn, I thought someone managed to put a Borla UEL on a lawn mower.

That would have been BA.

I think I will need to put it in the air as well and check for leaks.

The interesting thing is, I'll start the car, when the car is idling, it's loud, if I move, then press the gas to get it the same RPM, the noise is significantly different and lower.

Because when you first start the car, the car is programmed to warm up the car asap. high retarded ignition and open throttle.

So when you first start the car and it idles close to 2k will be much louder than 2k when you are moving the traffic

That's probably because the gas/sound is quickly moving past the gaskets and flanges versus slowly pulsing at idle and pushing out via the leaks. If you think about it in a fluid mechanics way it makes sense.

I thought I had a leak...we checked and found nothing, may have to double check. Either way thanks for the info. I thought I was crazy, and felt bad when we found nothing. I'm gonna feel like a total asshat if we take them off and they aren't warped.

just the way uncatted uel sounds...

A month ago, when we heard that Borla had delayed their UEL release date for another month or so because they had found something, I'm sure the warp was the problem they had found.

They shipped their pre production model like that to make economy and avoid big waste.

If only 40% of their customer ship it back to them for a replacement they will save 60% in their pocket !!!

:paddle:

I agree 100% with the opinions that your flanges are probably warped. Borla sent me a warranty replacement and they were warped more than the first one. Same exact noise as the OP. Visual evidence of blow by on the gaskets (stock & grimm speed MLS). Hopefully third time is the charm...

BTW Speedfactory has been an AMAZING help dealing with this. Best customer service I have had in a very very long time. Definitely will have more of my business in the future!!

Yup, I can believe that.

Shit, my replacement gets here tomorrow. If the flanges are still warped I'm gonna be PISSED!

I had the same issue with just the nameless axle back and catted OP/down pipe. Its only at idle when first starting up. I put it in gear and back out the garage and its gone.

Any chance you could throw up a video on youtube of your exhaust? I'm wanting to get a similar setup (Borla UEL + stock exhaust). Thanks!

yeah a stock exhaust + Borla UEL video would be awesome!

already done
http://www.ft86club.com/forums/showthread.php?t=31761

I ordered a special mic for the go pro to get the best sound I can. for now thats what I got

I took a video of the noise... It's not nearly as noticeable with a camera phone. I'll have to get the real camera out and give it a shot. I also took a few pictures of what looked to me like could be a bent flange.

[ame="http://www.youtube.com/watch?v=ymUb6OOZeo4"]Borla UEL Lawn mower - YouTube[/ame]

In the picture it seems to flare out in these two spots. I have the bolts torqued down rather tight, but it still seems bent to me. Thoughts?

[IMG]http://i.imgur.com/S32dPgq.jpg[/IMG]

Mine gets here tomorrow as well, hopefully we will both be good

If you torque the bolts too tight it may warp the flanges as well, the fire ring compresses in the center of the gasket to make the seal, torquing the flanges too tight can bent the ears in

Torque spec is 25-30 ft-lb if I remember correctly, same for the bolts where you bolt it to the head if it follows standard subaru procedure

Wonder if Borla is enjoying these warrantied returns. I'm glad you guys are at least covered, but Borla should really step up their game. The price of this header is sure showing in the quality. I'm assuming this isn't happening to everyone though, but this looks like a high amount of reports since Borla has finally released it out.

Their customer service is excellent. It was painless to start the return process, I am getting a replacement shipped to me with a return box for the old one, so no down time.

If the new one is warped as well, I might be considering other options though.

http://www.grimmspeed.com/catalog/pr...products_id=32

Worth a shot.

I ordered a set as soon a I found out borla was shipping a new header

I agree!

Hello,

I would like to place an order with Grimmspeed but I need your help to order the right exhaust gasket that I need.

I'm installing a Greddy SP elite axle back and I want a spare gasket for that exhaust joint just in case I need one.

I'm also installing a borla UEL header and I have found their manifold to headers gasket 22% thicker than OEM. Great for only 22.99$ for the pair !

( GrimmSpeed™ Subaru Exhaust Manifold to Head Gasket(pair) - Dual Port (14038AA000)[020001] )

I also need the gasket that goes between the headers and the overpipe. The oem part number for this would be '' 44011AG000 ''.

They have multi layer exhaust gasket 2X thicker than OEM and this could be better because people who are installing Borla Headers are having exhaust leak problem because of the warped flange onto the headers. So thicker gasket could be helpfull for that kind of situation.

Anybody knows which one I should order from them for the header to overpipe connection and for the axle-back ?

https://www.grimmspeed.com/catalog/advanced_search_result.php?keywords=exhaust+gasket &x=40&y=6


Thank You.

No you don't need MY help. Do some research. I don't help people.

Hey! Good thing i stumbled upon this thread (Honestly I just really liked the title) ;)

We currently do NOT offer the correct gasket for the header -> overpipe connection. We actually will have one soon, but not yet unfortunately. So I would recommend either oem or oem+silicone for now.

The head -> header gaskets fit though. Let me know if you have any questions or anything, or give us a call if you need anything.

Chase

how thick are the flanges? i think revworks used 1/2" flanges to prevent something like this.