Shifter

So, just for ****s and kicks I thought I would post this and vent a little.
I recently purchased these kleemann headers. They were purchased used, but and I quote in "basically brand new" condition. Upon install, by myself, at my dealership, a 10 year master tech, not 10 miles later a sever leak had appeared.
Come to find out rear cyl on the right bank had totally separated from the flange. After removal, and closer inspection, it appears that the weld was not a good one. The weld should be the strongest point, and the metal around it should break before the weld. Now, I am not a welding expert. So if there are any chime in. But, from what I understand the temperature must not have been right, and the weld never penetrated properly. As I am not the original purchaser, Kleemann will not do anything.

Now I am left to have it repaired myself. I am almost worried that the same will happen to another flange, so may get them all re welded.

03'55AMG

Looking at the welds, I would assume they did not have the amperage set right for the type of metal in question. If I were you I would grind it down and re-weld it myself.

_AMG_

Looks like a clean break, would definitely weld those back.
I would purge weld them so you have a strong, clean weld.

theeddie

after i broke mine 3 times i threw those pieces of junk in the trash.

Sir-Boost-a-Lot

iTrader: (1)

You bought used parts. Suck it up and repair it, and get back to life

It could have been a problem in manufacturing, or it may have been fatigued after the fact. It would cost more to find out than what the header is worth, and most certainly more than a repair. That's a five minute job with a MIG.

For good results, tack it back in place on the car, then remove to get a clean weld. Or for best results, do the whole repair with it bolted to a spare head.

jt2ma71

Atleast it was a clean break. Grind it down, have it welded and go have fun again!!

I suspect it was a poor weld to begin with. Maybe poor penetration i dont know only did basic welding in school.

Looks simple enough to fix though. Unless you want to get rid of them cheap ill take them off your hands and fix them :P

slownrusty

Typically a weld is stronger than the surrounding steel by a factor of 10 (give or take).

That is a VERY easy fix and as everyone has chimed in and mentioned, grind it down, and make sure you have a good root weld and cap weld with thorough penetration.

Exhaust manifolds crack all the time, even super expensive ones, so don't feel bad.

c32AMG-DTM

Every set of Kleemann headers I've ever seen, are uncoated, polished stainless steel.

Not trying to stir any pot, but are you sure you actually received what you think you purchased?

berti_00

^^previous owner looks like he may have coated them with high heat header paint!!

e55amgrocket

They were coated with Cerakote ceramic coating.

Shifter

It will be repaired. I'm making a solid flange to bolt it to to have it welded. As i dont have a spare head lying around There are cracks at the collector also. Will prob end up having them all rewelded, and TIG welded not MIG.

Exotic-metal55

Easy to fix and if you like, you can ship it to me and I will weld them for you. You may also want to use flex couplings on your exhaust (if you dont have them) to dampen the vibration on all the pipes and welds.

komp55

Good suggestion.

Now is also a good time to closely inspect your motor mounts. If they're going bad or are already bad, the resultant engine movement will easily crack most headers.

Sir-Boost-a-Lot

iTrader: (1)

Also, oblonging the holes on the front and rear primaries will allow for a little thermal expansion that stainless headers can suffer from.

03'55AMG

Is there a specific reason why you would go TIG instead of MIG welding? From my experience, MIG would be the way to go, because it is easier to control and can produce stronger welds than TIG can.
Actually, Aren't TIG welds more ductile than MIG? Maybe TIG would be the way to go here.

tbal

This

FT-Performance

Good luck getting it figured out!!

Rock

Kleemann headers do come coated when specifically ordered.......... that is what I received after my first set cracked. I love Kleemann products but I have seen more than one member post about their headers failing.

Good luck op.

Shifter

Thanks.

It should be fixed tomarow but i'll be out of town till July 5th, so then will have to reinstall after that. As some of you know, and are currently without, it sucks not having the beast to drive!

ArmbrusterJo

Good luck getting it figured out

c32AMG-DTM

Learn something new every day.

Thanks Rock.

slownrusty

I also ordered my Kleemans with the Jet-Hot coating also, it was a special order with of course a bit more time involved, but well worth it.

CharlyE500

Hopefully mine will last long....... but its only $1k new so if leaks just weld it. Even evosport shorties was more expensive than this mid range header.

Shifter

Happy to report I had all the flanges and collector re welded. It is reinstalled, and also had flex pipe put in. All seems ok so far.

03'55AMG

Easy enough fix huh? Glad to hear your'e running again!