So I was driving the other day and out of nowhere my car became extra loud. Normally I pay for those sort of things but this was odd. So I got home and inspected and found that the header cracked (see: rusted through) at the flange almost half way around. Heres a pic:



Anyways, my first thought was to get to welding but I have a sneaking suspicion that, that isn't going to work this time. As far as I'm aware you can't just buy one header either so this won't be cheap. What do you guys think? Got any ideas?

 

try welding it if not buy a header reducer and weld it on...but start saving for some coated headers...

 

I agree with the above, but doubt the metal there is thick enough to weld unless you muck it up with a pretty decent booger weld.

The way I would do it, would be to cut the bolts off, lose that back flange. Bolt another up there and tighten it. Cut back that rear pipe a few inches and put another expanded end pipe section. One end to slip over the exisiting pipe up there, plus gives you movement to slide forward and back to adjust it before you get tacked Tack to the flange, then unbolt it. Weld it on the bench nice and perfect, slide it back on, bolt it up, weld it on the back end or clamp it.

I agree though, start looking to replace it all. Once you find one, the rest are not far behind.