X pipe came apart on day 25 of 26 day road trip.This happened after 6300 miles on this trip I had to get it welded to get back to Florida. Header was put on April 2011 & has 40K miles on CVO Ultra Classic. I took the header off & found nothing loose as in muffler, hanging bracket or header or a rusted out pipe. It didn't break at a weld as it was 2" behind it on the right side.I was lucky as the heat shield kept it from possibly digging into the pavement!
I did contact Steve @ Fullsac & he said he has not had a problem like this!
I'm looking to replace it with another Fullsac header
Has anyone had this problem as I'm looking for a reason for this failure?
Thanks Dan
Just to be clear I have nothing but good to say about Fullsac and their products and service!
In an attempt to provide some possible reasons for the failure you mention I can think of some. I’m only bringing it up as a possibility. When installing and positioning the crossover pipe you will notice that it can be rotated so that the bracket that attaches to the trans case is in alignment within the same plane as the bracket on the crossover pipe. Any misalignment between these will introduce stress when tightened in place (less likely a cause in your case). A similar type of stress could also be introduced if the other header bracket were to be tightened or if it were bound up while tightening the exhaust flanges. Also similar stress can be introduced if the mufflers are not well aligned with their mounts in the back. Again not saying this is the case for your failure, and it could easily be a material failure in the metal tube. I'm sure Steve could better describe potential causes.
These are things that Fullsac has no control over after they ship the pipe. Not saying this is the cause of your failure, but I can see how something like this could cause a failure and without knowing about this possibility could cause one to come to a conclusion that it must be a fault in the pipe or material of the pipe.
Some companies are SO LARGE that they can just eat these type of failures even though in reality it is not a fault of their product. These type of problems are one of the reasons I have SO MUCH RESPECT for small businesses like Fullsac and how difficult it can be for them to succeed.
Fullsac has awesome products and service. I have the DX header and have also purchased the power cores. I have also had a failure and they stepped up in my case (which was different than yours) even though I’m not sure it was a failure with their product!
Awesome company and people!
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Topic: Fullsac Header breaks apart! Anyone have this problem? (Read 10936 times)