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Old 04-19-2005, 04:56 AM   #1
zeke21
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Default borla headers cracked so now...

now i need to figure out what to do. I know about the warranty but i believe it is only good if you have the original purchase receipt. I bought mine from ebay (they were new) and get the feeling that wont apply for the warranty. anyhow having to wait for the replacement and then sending the new one is just a pain in the ass especially if i have to do it over and over, seeing that borla has not fixed there header problem. However i should note that these are the single ports i have and i noticed more people seem to report problems with the single port than dual. Also the headers were only on the car for 2 months before they cracked a couple days ago. And the car was driven very normal as a daily driver.

after having a couple of muffler shops look at it they all seemed to suggest that maybe adding what they called a spherical joint on one of the tubes would help prevent it from cracking again. They figured the combination of the heat and the design of the borlas (stress because they are not equal length) is what causes them to crack at the collector. This joint would allow some flex in the pipe and possibly reducing the cracking factor. They also said something like having stainless steel for welds and the heat mixing sometimes causes breaks. So if the joint were adding and the cracked weld re welded without the stainless steel would this possible work?

what do you guys think as i am just trying to figure some things out. However the easiest would be to buy some equal length headers but that is kind of out of the budget.
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Old 04-19-2005, 05:49 AM   #2
svek
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i hear that "patching" up cracked headers lead to more cracks...not worth it. and since you say its a single port i dont know where you will find some equal length ones. i have never seen any single port equal length headers before. i suggest getting some headers custom done. since its single port that should be fairly easy. just 3 flanges 2 pipes and a Y joint
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Old 04-19-2005, 09:11 AM   #3
Aphex28
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umm... Just weld it back together, I'm not sure how doing that would lead to more cracks. I've been doing fine. Good luck
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Old 04-19-2005, 09:23 AM   #4
Hayes
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I thought Borla stuff was garunteed for 1x10\6 miles
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Old 04-19-2005, 10:01 AM   #5
Slack
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I'm doing an engine swap soon and I have some prototype(custom made) EL headers for the single-port EJ22 that I won't really need any more. Pm me if your interested in them.

Mick
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Old 04-19-2005, 10:03 AM   #6
Slack
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I had borla headers and I tried to weld them up many times, but they would always re-crack. They tend to crack between the pipes at the collector and it is very hard to get them sealed up. We believed it was vibration and stress causing the cracking.

Mick
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Old 04-19-2005, 12:09 PM   #7
gtwagon941
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Did you weld them with the right "weld" for SS? I have heard that it is important to do the welding special for SS or they won't hold.

.02

Jared
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Old 05-02-2005, 12:42 AM   #8
simprezl25
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the best way to go in brullen headers or cobb equal length headers. But you will sacrifce some of the the boxer sound that the borla makes.
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Old 05-02-2005, 10:11 PM   #9
99subi
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just weld them up this happens to every one with borla headrs for the impreza they kinda suck quality wise
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Old 05-02-2005, 10:51 PM   #10
Layman
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I called Borla without a reciept and explained I was the original owner, etc. They offered to warranty it, but I've had them welded in the meantime, and at this point I don't see the purpose in getting a new set just to have them crack again.

It shouldn't cost much to weld them.
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Old 05-02-2005, 10:53 PM   #11
orndog
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Is there a way to add a flex section? I bet that would help.
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Old 05-02-2005, 11:04 PM   #12
Layman
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Quote:
Originally Posted by orndog
Is there a way to add a flex section? I bet that would help.
Not really. It would help, but I don't think it's possible.

Unfortunately, I think it's just something we have to deal with.
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Old 05-03-2005, 10:57 AM   #13
omahasubaru
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Welding them is a perfectly fine option, good choice. Done right it won't re-crack or lead to other cracks.
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Old 05-03-2005, 04:54 PM   #14
MaxedOutRS2.5
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whats brullens webpage address?
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Old 05-03-2005, 05:21 PM   #15
gtwagon941
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not sure of the addy, but I'm pretty sure that they don't make their hearders anymore, if that is what you are intersted in. You will just have to find some used.

jared
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Old 05-04-2005, 09:35 AM   #16
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Or if you want equal-length, there's also TechWorks Engineering, from Canada:

www.techworkseng.com

Some of the nicest-manufactured Subaru parts on the planet.

(Next to Kartboy....)

=S2=
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