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Old 04-11-2005, 10:30 AM   #1
DreddRS25
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Default Borla's are cracked, need help deciding...

I've had borla headers for the past 6-7 months, which were purchased from a user either here or rs25.com. Good deal and the headers looked fine. Got them installed and loved the new sound. Recently I purchased a track pipe for the car, which I am looking forward to installing for some drag runs. (Or weekends )

When I crawled under the car to swap out the exhaust pieces I noticed some carbon build up on the headers. Right between where the final two pipes join before the cat. Not repairable . Anyhow.

Its a small crack and I haven't heard any sounds of a leak. Though a mechanic told me that it will only get bigger soon.

Do the borla's really give any kind of (performance) gain with only a ganzflow and unorthodox racing pulley (2.25 custom catback if that matters)?

Should I just take it off and try to sell the headers to someone who could repair them, try to find a shop to repair them, or ....? Heck I don't know.
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Old 04-11-2005, 10:34 AM   #2
Pat L.I.
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just have them welded. How do you know its not repairable?
Borlas give a very very small gain.
I would have them welded up and then forget about it.
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Old 04-11-2005, 10:44 AM   #3
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Knew someone would ask that

Honestly I had trouble with one of my exhaust bolts. Got everything off my cat except one bolt. Couldn't get it with the air tools I had and I was only up on two ramps which is very little clearance. (here it comes) So I tried sawing the bolt off, got pretty far, but then I just could get the hack saw in the well enough to finish it. (it was then that I noticed the headers were cracked)

So I thought an exhaust shop could a least help me get the bolt off, maybe swap in my pipe. Well they get the car up in the air and ask me what I want to do. I showed them the bolts and told them what I wanted, but they said no do to the legality issues (no cats). I tried to get them to just take two bolts off and I would do the rest at home, but no.

Before I left I ask them what I should do about the headers. I showed them where the crack was and they said that it will get worse. The mechanic said that it probably isn't worth repairing because it will probably crack around the new welds.
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Old 04-11-2005, 11:03 AM   #4
bobby d
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I thought Borla gave a million mile warranty?
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Old 04-11-2005, 11:11 AM   #5
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the best thing to do is call your local small time muffler shops( not like midas and stuff). Bring them the headers off the car and have them fix it, most the time shops like that will. The test pipe issue is iffy, i had the same problem tryin to get a shop to put mine on b/c if a shop gets caught putting on your test pipe or you get caugtht and say they did it, it's a $5000 fine. For that find i Performance/muffler shop and ask them on the phone first if they'll do it or your stuck putting it on yourself.
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Old 04-11-2005, 12:23 PM   #6
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Quote:
Originally Posted by bobby d
I thought Borla gave a million mile warranty?
Headers were used and the original owner did not have the warranty card or receipt.

I think I may just take the header and cat off at the same time. Since the stuck bolt is the connection between them. I'll hack saw the rest from there.

I'll put the stock manifold back on and see how much it would cost to have the borlas repaired.

I'll just deal with the track pipe myself. Figured it would be a big deal to have a shop swap it out. Converters at meineke start around $150, so I'll figure something.
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Old 04-11-2005, 12:35 PM   #7
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Quote:
Originally Posted by Pat L.I.
just have them welded. How do you know its not repairable?
Borlas give a very very small gain.
I would have them welded up and then forget about it.
Do not bother getting them welded. They will crack again and again and again. This happened to me and I ended up getting some custom headers made for my car. Please do yourself a favor and get rid of the Borla headers.

Mick
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Old 04-11-2005, 12:38 PM   #8
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Quote:
Originally Posted by bobby d
I thought Borla gave a million mile warranty?
Yeah, they do. You have to:

A) Put your stock headers back on and ship the Borla headers to them and wait for them to figure out if they will replace them or not.

or

B) Buy a new pair (at their price) and they will ship them to you and then you ship your old headers back to them and they will refund you the money if they want to honor the warranty.

Mick
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Old 04-11-2005, 12:45 PM   #9
sebtarta
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Borla headres do give some performance. Not much.

With a ganzflow installed and the borla headers, if your weekly driving is easy then you fuel consumption is amazing. you get about 360 to 380 miles per tank.

That is what i get, the only draw back is that when you are WOT the gas go down fast.
I have new borlas installed, had to wrap them up in order to get full efficiency out of them.
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Old 04-11-2005, 12:51 PM   #10
DreddRS25
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Yeah, my mileage went up with both Intake and Headers. Don't want to lose that.

Though I am tired of starring at a CEL.

I also had been considering wrapping the headers. Oh well...

Should I take the headers off ASAP or can I sit on this for a little while. The cat is coming off this week along with the header, so I can get that bolt off and at least replace it. Just need to decide to keep the borla's on for a bit longer or just put the stock piece back on. Thoughts?

I appreciate all the replies thus far.
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Old 04-11-2005, 12:54 PM   #11
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how does ganzflow give more mileage?? wouldnt the increase in airflow cause the ecu to put more fuel to keep the a/f ratio??
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Old 04-11-2005, 12:58 PM   #12
DreddRS25
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I'm pretty sure unless your cruising above 3500-4000rmps the cars runs leaner. Do to the better air flow the engine can make the same power with less fuel. Not 100% positive.
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Old 04-11-2005, 01:00 PM   #13
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Quote:
Originally Posted by Slack
This happened to me and I ended up getting some custom headers made for my car.
Mick
Could you give us an idea about how much you spent for your custom work, and did you go to a small time shop or something like meineke or midas?

Last edited by DreddRS25; 04-11-2005 at 01:00 PM. Reason: mispelled something
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Old 04-11-2005, 01:04 PM   #14
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what generation headers? borlas have a million mile warranty (ship the headers to them and they will send u a new one), unsure if its transferable, but how would they know anyways...
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Old 04-11-2005, 01:10 PM   #15
DreddRS25
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Quote:
Originally Posted by Jejunum
what generation headers? borlas have a million mile warranty (ship the headers to them and they will send u a new one), unsure if its transferable, but how would they know anyways...
I'm pretty sure these are either 2nd or 3rd generation. The could be at least 5-6 years old. They came off a 98 legacy.

I'll send borla an email to see what they think. They'll probably say "where's the warranty or receipt", but if they do honor it that'd be nice. Can't hurt to try, but I'm not shipping anything unless I have an idea of the result.
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Old 04-11-2005, 01:52 PM   #16
sebtarta
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Quote:
Originally Posted by DreddRS25
I'm pretty sure these are either 2nd or 3rd generation. The could be at least 5-6 years old. They came off a 98 legacy.

I'll send borla an email to see what they think. They'll probably say "where's the warranty or receipt", but if they do honor it that'd be nice. Can't hurt to try, but I'm not shipping anything unless I have an idea of the result.

send them an email telling them that you cannot find the receipt. that you bought it a long time ago, and form one of the performance websites.

they should be able to help you.


in terms of changing the headers i would change to the stocks for now. Take a picture of the crack if you can, i would like to see how big and where the crack is. It could be as easy to fix them or as to say "Borla, i want to use the warranty!!!"
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Old 04-11-2005, 02:37 PM   #17
DreddRS25
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Probably tonight after work I will squeeze under there and take a pic.

Imagine getting a paper cut between your index and middle fingers. That is what the crack would look like. But pics to come.

(excuse the graphic nature of this post )
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Old 04-11-2005, 03:02 PM   #18
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Email sent to Borla, I'll post their reply.
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Old 04-11-2005, 04:54 PM   #19
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Quote:
Originally Posted by DreddRS25
Could you give us an idea about how much you spent for your custom work, and did you go to a small time shop or something like meineke or midas?
I spent less than 100 bucks on them. I had a buddy with a shop and a welder, so it was convient for me.

For you I'd suggest finding a local shop that does a lot of custom exhaust work (like muscle cars) and get a quote. You can either have them make a custom header for you or you can have them make a custom header + cat section (with a CatCo high-flow cat $40~60) for a decent price. You can order the cat yourself and then have them make the rest. If you get them to make a header and cat section, you can eliminate that S-bend in the stock exhaust design.


Mick
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Old 04-12-2005, 04:10 PM   #20
DreddRS25
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Let's try a picture. Out of focus, I know. I just reach under with my camera and zoomed in. When I have it up on ramps I'll get a nicer shot. Most of the black is carbon, but I fear the crack may actually be that big.

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Old 04-12-2005, 05:29 PM   #21
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Old 04-12-2005, 05:38 PM   #22
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You live in TX, so rust shouldn't be a big problem. That being said, you can purchase mild (aluminized) steel piping, mandrel bends (J-bends, U-bends, etc), and hi-flow cats all from either JC Whitney or Summit for not a whole lot. If you don't have any local Subaru folks that would know how to help, then here's what I would do:

1) Get an idea of what style of header you want (stock/borla-ish, MRT-style, etc)
2) Ask around and find a shop that does a lot of custom exhaust work.
3) Tell the shop what you want and have them figure out how much exhaust piping, bends, etc. that you will need and either write it down yourself or have them make a list.
4) Take that list and go online to either of the above mentioned companies' websites and find the best pricing, buy parts, and set up an appointment with the exhaust shop and get'er done.

I personally do not recommend Midas or Meineke, because, from personal experience, they don't like to 'mess around' with custom jobs for the most part.

Mick
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Old 04-20-2005, 02:53 PM   #23
DreddRS25
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Still no response from Borla

At least a "tough luck" email would be nice to receive as opposed to no email reply.

Slack, the picture above that you posted. Was that a shot of a rewelded header or is that a shot of what your header looks like.

Anyone here used a track pipe with Borla headers and then switch back to the stock manifold? Since my borla's are cracked I will putting back on my stock piece. I'm just kind of wondering what major change in sound is prevalent. Performance is second for me.
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Old 04-20-2005, 03:33 PM   #24
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Myborla headerscompletly split inhalf... its been leaking forthe past 2 months but now its COMPLETLY split in half... I called borla today and they basically said sucks for you...

I don't know what to do Idont have stock headers lying around cuz I bought the carwith theborla headers andborla catback alreadyinstalled....
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Old 04-20-2005, 03:57 PM   #25
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Yeah, I emailed Borla with some questions and never got a response. I bought a header used, otherwise I would never use a Borla product. I mean, do all their headers crack?
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