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DC Sports Header potential crack issue

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    DC Sports Header potential crack issue

    Hi all, I need some more experienced eyes on this potential problem.

    I just got my DC SPorts 4-2-1 Headers with the flex pipe, all ceramic coated inside and out! Totally awesome, until I inspected them and found this at the base of the 4-2 header portion:



    This cut does not penetrate even 10% of the metal, but I wanted to run this by the community to see if you all thought it would lead to full on cracking after installation and use. If more pictures are necessary, let me know.

    Thanks for the help .
    *** Think of others before thinking of yourself. ***
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    MRT
    Selling on Ebay!

    15.10 @ 90.42mph
    The quest for 9s ceased, now the goal is a circuit track monster!
    Current fastest Laguna Seca Lap: 1:52.889

    #2
    that is what would be called a crack propagation point. it's the weakest point in the metal and the easiest point at which the piece would fail. the header flange is a pretty high-stress area with the heat in the area and the weight of the header hanging off of there. If it is, as you say, only 10% of the way through, I would take this to a welder and have them fill that crack.

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    Comment


      #3
      Awesome. Thank you for the info. I was hoping not to have to do a return on that, and I have a contact welder. Since these are ceramic coated steel, should I have the welder fill the area with stainless steel to prevent rusting?
      *** Think of others before thinking of yourself. ***
      ********** Spread love, not hate. ***********
      ****Lift others up with kind and helpful words****

      F20A_CB7, I miss you, but I will see you one day.
      "Nothing a little prayer can't fix."


      MRT
      Selling on Ebay!

      15.10 @ 90.42mph
      The quest for 9s ceased, now the goal is a circuit track monster!
      Current fastest Laguna Seca Lap: 1:52.889

      Comment


        #4
        looks superficial just like the line to the right of the tube that got coated.

        to weld it theyll have to grind away the coating near it, but honestly it looks more like a scratch then something to worry about.

        when theres a crack theyll drill holes at each end of the crack and fill it with a tig bead. eg: o-----o

        i wouldnt trip.

        Comment


          #5
          it looks like their flat steel sheet stock was scratched before they cut out the flange template. Maybe some runaway tooling that gouged it. Considering the welding and coating were done AFTER and overtop this defect, I would guess that it is more of a cosmetic issue rather than structurally compromising.

          I would run it, and only get it ground and welded if it happened to fail in the future.

          May just want to ask DC what they would offer in terms of warranty, and if they cover all the expenses and its easy to do, a swap out might be a good idea... but personally I don't think I would bother.


          - 1993 Accord LX - White sedan (sold)
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          Current cars:
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          Comment


            #6
            Nothing to worry about. It will not crack.

            Comment


              #7
              Originally posted by cp[mike] View Post
              it looks like their flat steel sheet stock was scratched before they cut out the flange template. Maybe some runaway tooling that gouged it. Considering the welding and coating were done AFTER and overtop this defect, I would guess that it is more of a cosmetic issue rather than structurally compromising.

              I would run it, and only get it ground and welded if it happened to fail in the future.

              May just want to ask DC what they would offer in terms of warranty, and if they cover all the expenses and its easy to do, a swap out might be a good idea... but personally I don't think I would bother.
              The headers I got come with a 12 month limited warranty. I will have to check the documents for specifics, but I'm glad to know that I don't need to stress over it. I don't want to ruin any of the ceramic coating in order to fill the scratch/gouge. Thanks everyone!
              *** Think of others before thinking of yourself. ***
              ********** Spread love, not hate. ***********
              ****Lift others up with kind and helpful words****

              F20A_CB7, I miss you, but I will see you one day.
              "Nothing a little prayer can't fix."


              MRT
              Selling on Ebay!

              15.10 @ 90.42mph
              The quest for 9s ceased, now the goal is a circuit track monster!
              Current fastest Laguna Seca Lap: 1:52.889

              Comment


                #8
                I just noticed something alarming in the directions. DC sports says to reuse the gasket that's on the car now when the stock headers are removed. I know for certain that gasket has been on the car since at least '96. Are they serious? I went over the directions many times, so I am sure I did not read the directions wrong. Even my service manual says to replace it after removal.
                *** Think of others before thinking of yourself. ***
                ********** Spread love, not hate. ***********
                ****Lift others up with kind and helpful words****

                F20A_CB7, I miss you, but I will see you one day.
                "Nothing a little prayer can't fix."


                MRT
                Selling on Ebay!

                15.10 @ 90.42mph
                The quest for 9s ceased, now the goal is a circuit track monster!
                Current fastest Laguna Seca Lap: 1:52.889

                Comment


                  #9
                  Originally posted by af_1132 View Post
                  I just noticed something alarming in the directions. DC sports says to reuse the gasket that's on the car now when the stock headers are removed. I know for certain that gasket has been on the car since at least '96. Are they serious? I went over the directions many times, so I am sure I did not read the directions wrong. Even my service manual says to replace it after removal.
                  they didnt give you new ones?? even cheap ebay setups included new gaskets..

                  http://scegaskets.com/

                  http://www.summitracing.com/parts/sce-9400

                  if youre talking about header to head gasket and you have the ishno MLS type, they can be reused, as this is what I did instead of the aluminum crush type included.

                  Comment


                    #10
                    I am talking about the header to head gasket, they did give all other gaskets for the other flanges, thank goodness. Now for the type, I checked my '93 service manual and they look like product 9402 on page 57 of the SCE Gaskets catalog. A few days ago, I ordered a copper version of this from Mr. Gasket on Ebay. I'll post a picture when it arrives. Thank you so much for that SCE Gaskets resource!
                    *** Think of others before thinking of yourself. ***
                    ********** Spread love, not hate. ***********
                    ****Lift others up with kind and helpful words****

                    F20A_CB7, I miss you, but I will see you one day.
                    "Nothing a little prayer can't fix."


                    MRT
                    Selling on Ebay!

                    15.10 @ 90.42mph
                    The quest for 9s ceased, now the goal is a circuit track monster!
                    Current fastest Laguna Seca Lap: 1:52.889

                    Comment


                      #11
                      Originally posted by illinois_erik View Post
                      they didnt give you new ones?? even cheap ebay setups included new gaskets..

                      http://www.summitracing.com/parts/sce-9400
                      Actually, now that I look again, they didn't give me a collector gasket as well . Two O-rings for the machined grooves were included. Nothing is mentioned about a collector gasket in the directions; but, if leaking is indeed a problem at this location without a collector gasket, then I will order one.
                      *** Think of others before thinking of yourself. ***
                      ********** Spread love, not hate. ***********
                      ****Lift others up with kind and helpful words****

                      F20A_CB7, I miss you, but I will see you one day.
                      "Nothing a little prayer can't fix."


                      MRT
                      Selling on Ebay!

                      15.10 @ 90.42mph
                      The quest for 9s ceased, now the goal is a circuit track monster!
                      Current fastest Laguna Seca Lap: 1:52.889

                      Comment


                        #12
                        Originally posted by af_1132 View Post
                        Actually, now that I look again, they didn't give me a collector gasket as well . Two O-rings for the machined grooves were included. Nothing is mentioned about a collector gasket in the directions; but, if leaking is indeed a problem at this location without a collector gasket, then I will order one.
                        Ok the two rings are stock style gaskets for like an A6 downpipe. they should be good. I got a pair with my gasket set for an h22a.
                        I suggest using copper gasket sealer/adhesive spray too on both flange sides and gasket.

                        Comment


                          #13
                          Thank you so much for your help. I ordered that flange gasket and I found that my local Autozone carries the copper spray, so I'm set for a full install this weekend! I'm mating these headers with Magnaflow from there on back.
                          *** Think of others before thinking of yourself. ***
                          ********** Spread love, not hate. ***********
                          ****Lift others up with kind and helpful words****

                          F20A_CB7, I miss you, but I will see you one day.
                          "Nothing a little prayer can't fix."


                          MRT
                          Selling on Ebay!

                          15.10 @ 90.42mph
                          The quest for 9s ceased, now the goal is a circuit track monster!
                          Current fastest Laguna Seca Lap: 1:52.889

                          Comment


                            #14
                            Originally posted by af_1132 View Post
                            I am talking about the header to head gasket, they did give all other gaskets for the other flanges, thank goodness. Now for the type, I checked my '93 service manual and they look like product 9402 on page 57 of the SCE Gaskets catalog. A few days ago, I ordered a copper version of this from Mr. Gasket on Ebay. I'll post a picture when it arrives. Thank you so much for that SCE Gaskets resource!
                            Yup, that's the correct gasket.



                            Comment


                              #15
                              Originally posted by af_1132 View Post
                              Thank you so much for your help. I ordered that flange gasket and I found that my local Autozone carries the copper spray, so I'm set for a full install this weekend! I'm mating these headers with Magnaflow from there on back.
                              youre welcome no problem hope its buttery smooth! it ought to sound awesome, that magnaflow systems a pretty penny.

                              Comment

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