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?
https://lh3.googleusercontent.com/tZ...=w1741-h979-no
@Shiv@Openflash

One year warranty. Right there on the website.

Yeah there was another post a little while ago. Seems to only be a few though.

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.

Here's mine. About 10k miles.

Attachment 135337Attachment 135338

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How many miles on the car? How are your stock exhaust hangers?

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.

Interesting point.......that wouldn't surprise me ...... but, I :iono: fer sure.


humfrz

43k on the car. Exhaust hangers aren't broken. Do these go bad?

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

Well don't just tell us... show us!

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.