Subaru Exhaust headers - Recommendations?

joetiger · Posted: Wed Oct 09, 2013 6:30 am Post subject:

Well, I noticed a bit of a popping sound from my exhaust last month, and it looks like my Kennedy header has bitten the dust. I've got seam cracks in both of the welds at the turn below the heads. 7 1/2 years and 50k miles of hard service finally took its toll.

I could probably get it welded up, but...

In somewhat related news, my freaking tailpipe is GONE. Broken off at the base of the muffler (Ernst) so repair looks unlikely. I have no clue as to how or when it happened. It's certainly rusty around the outlet, but it doesn't seem so bad that the tailpipe would FALL off. I can't think of anything I've done recently that would have caused it. Haven't gone off of any sweet jumps or heard any massive backfires.

Oh--the cat is also rattling like crazy. Talk about a total system meltdown.

I'll get some pics up later for the sake of posterity when I get a chance, but basically my entire exhaust system appears to be trashed so I might as well replace it all. Back when I installed all of that stuff, I thought it would be the last thing to fail.

Damned thing sounds like a Volkswagen right now. Very Happy

Time to drop some cash. Sad

_________________
Joe T.

'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'04 GTI 1.8T
'04 Golf R32

"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron

"Still, it's good to be afield."--VWagabond

Available Now! Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present

www.josephtrussell.com

Team WorldTour · Posted: Thu Oct 10, 2013 12:45 pm Post subject:

<Problem Solved>
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1990 Feldjäger Syncro AAZ
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H6 Subaru Engine Swap Thread
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Franklinstower · Posted: Fri Oct 18, 2013 10:06 am Post subject:

I knew my Gen 1 SC header was getting close to needing replacement, didn't know it was this bad though:

This is at the collector on the 2/4 side (that's the 1/2 side for you VW guys)

The crack is close to 180 degrees. (or 360 if your Karl Malone!)

Image may have been reduced in size. Click image to view fullscreen.

now what? Weld it? Try Stans? Try the new SC Stainless? $5 bills is hard to swallow. Especially when you see all those nice Subaru headers for less than 1/2 that.

Paul
_________________
'89 Westy - EJ25/22 Frank 4.44 5mt
'75 Miami Blue Sunroof FI Standard Bug

Farfrumwork · Posted: Fri Oct 18, 2013 10:59 am Post subject:

^^yeah, but any exhaust manifold for a subaru that cost 1/2 of a conversion header won't be much of a header either (good ones costs quite bit more)

The key for cost comparisons in this case is volume... LOTS of subarus running around compared to converted vanagons.

My SC gen1 has some cracks, but they certainly aren't as open as your picture shows. I have a hole in my muffler now that is louder...
I will need some header work/replacement in the near-ish future.
_________________
sold Sad

-> '85 Wolfsburg Syncro / 'Built' DOHC EJ25 (a great machine!)
'07 Legacy spec.B, road tuned stgII
'17 4x4 Sprinter, stone grey, SMB pop-top, on 33"s

"Blood stains, speed kills - Fast cars, cheap thrills - Rich girls, fine wine - I've lost my sense, I've lost control, I've lost my mind"

Farfrumwork · Posted: Fri Oct 18, 2013 11:05 am Post subject:

joetiger · Posted: Tue Oct 29, 2013 7:23 pm Post subject:

By the time I finally got around to buying a header, my old one was broken completely. Because I don't have a spare car right now and really need my Vanagon, I went with what I know and ordered another Kennedy, now in Stainless and only $300.

I called them Thursday afternoon and it was here today.

I had grand plans to try something differrent, but I just didn't have time.

Easy installation, everything lined up nicely and bolted right up. I did notice that the wires on my Oxygen sensor were a bit twisted up and exposed, so I cleaned them up as best I could and made sure the insulation was down over everything.

I don't know what I did, but the van runs like a bat out of hell (relatively.) I mean it has never accelerated like this, even when I first did the conversion. The puzzling hesitation that I had around 2200 RPM is gone.

Just a theory, but it is possible that my OXS hasn't been functioning correctly for a really long time? Where the tail pipe broke off of my muffler, there's a ton of black soot around that end pipe area of the muffler. Could I have been running rich this whole time?

I don't know. What I do know is that I don't have to ride my bike eight miles to work in freezing rain tomorrow morning, and that makes me happy.
_________________
Joe T.

'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'04 GTI 1.8T
'04 Golf R32

"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron

"Still, it's good to be afield."--VWagabond

Available Now! Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present

www.josephtrussell.com

syncrodoka · Posted: Tue Oct 29, 2013 7:45 pm Post subject:

insyncro · Posted: Wed Oct 30, 2013 5:54 am Post subject:

Whoa.....stainless Exclamation

boroko · Posted: Fri May 16, 2014 11:40 pm Post subject:

I must be missing something. After reading 12 pages and getting all excited about RMW's 4-1 and Vanaru's pretty systems, I can't find them on their respective sites.

I was really curious how the 4-1 worked out for torque. Were these just too challenging to continue making?
(of course, I could just call them, but this puts the info out there for all who are still looking).

Bo
_________________
'87 SyncroWesty: Smokey the Turtle, '85 SubiWesty: Chappie, '84 GTI, '86 GTI in full Rally trim,
previous: 2 Syncro tin tops, 2 Vanagons, 3 busses, 3 Ghias, 2 Jettas, a 411, a gas and a diesel Bunny and about 25 Beetles, one that only drove left.

OhChit · Samba Member Joined: January 29, 2004 Posts: 271

I'm going to need a New SS Exhaust Header soon for my Subaru Conversion.
The current one is an earlier Small Car mfg. Cracks keep showing. Kind of don't want to go with another S.C. after spending good money once already on junk that had to be welded many times, just not comfy with there product. They got me once and will offer no credit on there bad product in exchange for a new one.

So was wondering has anyone done a price point comparison. Meaning whats out there and at what price?

Basically who makes what that fits the stock exhaust configuration Question

_________________
Fast Cars, and Slow Women Makes me DrooL.

JeffRobenolt · Posted: Sat May 17, 2014 7:14 am Post subject:

Jake de Villiers · Posted: Sat May 17, 2014 8:10 am Post subject:

insyncro · Posted: Sat May 17, 2014 9:13 am Post subject:

The new SC headers are vastly improved over the Gen 2 stock they had.

GreggK · Posted: Sat May 17, 2014 6:59 pm Post subject:

Ive been using Stans 2pc header for about 4 years now free. Ive been using a mastercraft/Burley oil pan and mount. I also had to modify my SC j-pipe to mate with the ball and socket type joint at the header. He has pictures on his site. Google stans headers.

GreggK · Posted: Sat May 17, 2014 8:48 pm Post subject:

I meant to say crack free. Also... after 4 years of Colorado winters the hearder showed no rust. I believe I chose the chrome finish. I have recently had it jet-hot coated but cant comment on that yet. Im still working on my van and is off the road. There are pictures on his site. Google stans headers. Stan also replicated my modified SC j-pipe. His work is top notch. Give him a call if your interested in his product. He shead some light on his experience with vanagon/Subaru headers that made me even more comfortable with my choice.

Jake de Villiers · Posted: Sun May 18, 2014 10:13 am Post subject:

Jake de Villiers · Posted: Sun May 18, 2014 10:19 am Post subject:

zeohsix · Posted: Sun May 18, 2014 5:47 pm Post subject:

BeetleGun1 · Posted: Sun Oct 12, 2014 8:55 pm Post subject: Subaru conversion header failures

It might be interesting to note that motorcycle and aircraft use multiple pipe sections in their stainless steel exhausts held in place by springs, these springs allow the exhaust system to move and flex. This movement helps eliminates cracking at welded joints and long stress sections of pipe. The sectioned exhaust systems are also a whizz to remove and install. I'm converting 1990 2WD to 3.3L Subaru and plan on making my own exhaust, which will be similar to a racing motorcycle set up in construction. Stainless steel tubing must also have the inside diameter purged with inert gas for proper welding. Will let you know. I own 4 motorcycles/ 2 for racing, 2 vanagons, 3 type1's


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Subaru Exhaust headers - Recommendations?
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