stolarzj

I have a leak somewhere at the front of the car, kind of leaning towards the headers. I can't see any black soot anywhere in that area, I saw a little bit on the front of the cat, but that is not where the noise is. Is there a general place where these headers crack? I can't find any cracks on the headers, I've looked from the top and the bottom?? The gaskets for the collectors looked fine when I had the exhaust out for the clutch, and I used new bolts for reinstall and they are all tight.

SoCal Driver

Steel tube header for cylinders 1 and 4 crack under the welded on brace.

Jim @ EuroWerks

The only place I've seen the "S" leak was at the manifold gaskets. Never seen one crack. When the car is stone cold run your hands around the flanges be quick! Gets hot fast! You should feel the leak!

stolarzj

Thanks.. I think I'm just going to replace them. I so far I got the 2-3 header unbolted, the gasket appears to just be a copper ring? It looks fine, maybe one of the others is the problem.

Also something interesting happened, I was removing the front bracket bolt for the coolant pipe that runs across there. When I got the bolt to move I heard air like I depressurized something. There appeared to be pressure in that bolt hole. There was also really bad smelling black oil in that hole..

Jim @ EuroWerks

If at one point oil (or lube) got in this bolt hole and was there for a long time it would have burned. really old burnt oil stinks real bad! Keep going, with the manifolds off watch for those carbon tracks!

joseph mitro

when i rebuilt the head on my 944S, and removed the header for cylinder 1 & 4, the metal bracket that is supposed to be welded to the header pipe on #1 simply broke off completely (that is, it was already broken). i couldn't see this when the headers were still attached to the car - only became apparent when they were removed. welded the bracket back on - good as new. after being repaired, i no longer have that annoying "tick-tick-tick" when the car idles from an exhaust leak

stolarzj

It's definitely a cracked header, it is the CYL 1/4 header, it cracked in the reinforced area where the two pipes come together. I'll attach a pic of it. Think it's something my local machine shop can handle? I know some people didn't have luck with welding them, but new ones are not an option..

Mike S

You might be able to get another one from a salvage yard for what it would cost to weld em.

stolarzj

Only problem is the header appears to be specific to the S, so I think it's going to be a little difficult to find a good one..

SoCal Driver

Told you so!

Jim @ EuroWerks

Make sure you find a good welder that knows how and can weld stainless When we have a manifold welded in the shop we bolt it to a head or something rigid so it doesn't warp. Socal, you are so smart!

stolarzj

So you think it's within a machine shops realm to do this? Or should I find a welder in my area?

Jim @ EuroWerks

Definately a welder. If a gusset has to come off to repair it, just make sure it goes back on. A good welder will know this. You might want to bolt it to a peice of steel so it doesn't warp. It will save you headaches. A fabricater would be great. We repair them all the time. A welder should give you a much better price than the machine shop because the machine shop will take it to the same welder then mark it up to you. How many TIG welders have you seen in a machine shop?

stolarzj

I see if I can find a good local welder.. I guess if I can't find a good one, Charlotte's only a day trip...