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Old 06-10-2002, 10:20 AM   #1
dcoty
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Angry Borlas cracked! Whats my best header option?

Hey guys (and gals),
I just heard back from my dealer about a bad O2 sensor I had replaced and the noticed my headers are cracked.

I have the 2nd gen borlas (well had ) so what should I go with now? The 3rd gen borlas?, brullen? Tell me your experiences with your headers please? I want the best!

Thanks everyone, i appreciate it!
Dan Coty

Anyone know why they cracked? I know several people have had this happen to them too.
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Old 06-10-2002, 10:24 AM   #2
rupteur7000
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give borla a call, they have a life warranty, i think they give you a choive between new ones or free fix at your local muffler shop!!
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Old 06-10-2002, 11:01 AM   #3
jeffg
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Yes, just call Borla. Get the new headers. I did exactly the same thing, and the new ones are much better.

J
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Old 06-10-2002, 12:14 PM   #4
dcoty
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Sweet!

Whats the number, that all i need, please someone give me the number so i can cancell my order with cobb!

###
please!

Thanks for the quick replies everyone, i really appreciate it, you saved me a lot of money!
Dan Coty
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Old 06-10-2002, 12:40 PM   #5
Jademonkey
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Did you buy them used? Borla won't warranty if you are not the original owner.

From their website, here's the number for Borla. 877.GO.BORLA - 877.462.6752
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Old 06-10-2002, 01:18 PM   #6
SoobATV
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If you decide that you'd like new headers, the Brullen equal length header is veeeery nice.
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Old 06-10-2002, 04:52 PM   #7
Poppa smurf
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Borla is awesome replaced my cracked gen3 headers with gen 4's turnaround with in 1 week
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Old 06-10-2002, 08:12 PM   #8
Section 8
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Quote:
I want the best!
Get the SYMS header.
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Old 06-11-2002, 06:48 AM   #9
Corey
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It seems as if your problem is solved. But for anyone else looking for the "best" header, I would not recommend the Brullen.

Corey
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Old 06-11-2002, 11:23 AM   #10
Yeoman
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My 3rd Gen Borla's are cracked, I'm just wondering what was the process, Cause It would be pretty expensive to put he stock ones back on, ship the old ones, then install the new ones. Would they send the new ones in good faith that they'll get the cracked ones back?

I bought them used but the original owner has all the paperwork and everything and is local.

and just off-hand, how possible is it to just repair it on my own? I haven't seen the crack (they're wrapped), but something like JB Weld hold up on a header?? Or anything???

thanks.
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Old 06-11-2002, 11:29 AM   #11
Section 8
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You could have someone weld the crack,but the problem isn't the metal, its the design. You will have to keep repairing them because they will eventually crack again. They were not given enough space to expand and contract without added stress, and this is what is causing the cracks. There are already a bunch of weak places in your headers, the crack that you noticed is only the first to fail completly. Others may be soon behind.

Greg
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Old 06-11-2002, 11:45 AM   #12
CosmoTheCat
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The headers are supposed to be direct bolt up replacements. It shouldn't take more than 30 minutes to swap them out if you've got ramps and a (14mm?) wrench or two.

Unless of course they got welded in.
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Old 06-11-2002, 12:01 PM   #13
dcoty
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Did anyones borlas make a rattle?? Mine make a hideous rattle (like a honda exhaust) when I slowdaon using compression braking at around 200-2500 rpm, its horrible, i have to put the car in neutral at 3000 rpm.

So i have to send them my headers then they sent me the gen 3's?

My brothger is very experienced in welding and wants to do that, is this worth it or will it void my garentee with borla if they crack again and I send them in?
Thanks for the replies
Dan Coty
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Old 06-11-2002, 12:15 PM   #14
Julian
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The Borla pipes are stainless, so your friend will have to have a TIG and be pretty good with it. Once you weld on the header, you will void the warranty.

If you have cracks in your header, then you have an exhaust leak, which is the "rattle" you might be hearing. Sounds sorta like a turboed old Beetle...
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Old 06-11-2002, 03:36 PM   #15
Jayson_K
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Quote:
Originally posted by Section 8
You could have someone weld the crack,but the problem isn't the metal, its the design. You will have to keep repairing them because they will eventually crack again. They were not given enough space to expand and contract without added stress, and this is what is causing the cracks. There are already a bunch of weak places in your headers, the crack that you noticed is only the first to fail completly. Others may be soon behind.

Greg

Has this problem been addressed with the new generation of Borla's? As others claim it has?
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Old 06-11-2002, 03:38 PM   #16
JSiwek
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I had mine professionally welded to fix the crack/leak.... Borla was more than happy to pay for it, and they referred me to a VERY nice shop.

The problem is caused by the little bracket that connects two of the pipes. When the pipes expand, this little bracket thing doesn't because it's not in contact with the actual exhaust gases. The pipes change size, but the bracket doesn't, and were it's welded to the two pipes cracks. The shop fixed this by cutting out that support bracket (it's totally useless and the new versions simply omitted it) and welding up any holes. They even listened with a stethescope afterwards to make sure there were no further exhaust leaks.

Anyway, it's been awesome since fixed... no more problems. Borla was very helpful.

OH BY THE WAY!!! TALK TO STEVE THERE, HE KNOWS ALL ABOUT THE SUBARU HEADERS AND WILL HELP YOU OUT!

Jeremy
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Old 06-11-2002, 05:18 PM   #17
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my replacement set of headers does not have the cross brace.

Part of the problem with the cross brace is the thermal expansion, as others have said, and Borla did not back flow the headers when they welded the brace on, so they created brittle spots.

J
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Old 06-20-2002, 01:04 PM   #18
Blindeye_03
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Quote:
Originally posted by jeffg
my replacement set of headers does not have the cross brace.

Part of the problem with the cross brace is the thermal expansion, as others have said, and Borla did not back flow the headers when they welded the brace on, so they created brittle spots.

J
So are the lastest gen headers cracking or did they fix this?

-justin
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Old 06-20-2002, 02:08 PM   #19
Jademonkey
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..i got my header a few months ago...and I was wondering why it didn't have that cross bracket. I thought I had some reject header...but i guess they didn't put that bracket on for a reason!
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Old 06-20-2002, 05:22 PM   #20
Kucheto
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Quote:
Originally posted by Blindeye_03


So are the lastest gen headers cracking or did they fix this?

-justin

I had Gen3 Borla header and I called them a while back.
Yes, Borla is aware of the issue and they replaced mine in a week (for free of course) for a Gen4 header, which doesn't have the connecting plate! Works and sounds awesome!
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Old 06-20-2002, 08:05 PM   #21
Frakk's2.5
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Dude I just got the borlas I think they are the 3rd Gen...(I bought them from SPO motorsports) I forgot to check with the guy who I placed the order with. how did you know that your header had cracked and how long did it take? tough luck, though that sucks...
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Old 06-20-2002, 10:34 PM   #22
grubaru
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Quote:
Originally posted by Section 8


Get the SYMS header.
bump bump
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Old 06-20-2002, 10:51 PM   #23
Blindeye_03
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Quote:
Originally posted by Section 8


Get the SYMS header.
HAHAHAHAAAHAHAAAA if you have +$1500.

Not worth it...

-justin
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Old 06-20-2002, 11:13 PM   #24
Poppa smurf
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for the Gen 3's i think they crack above the support and you should see a carbon build up on top between the two pipes at least thats what happened with mine. I took a picture you may want to search for it.
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