Topic: Fullsac Header breaks apart! Anyone have this problem? (Read 10915 times)

danner55 · « **on:** November 12, 2017, 12:16:55 PM »

X pipe "B" 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

FLSTFI Dave · « **Reply #1 on:** November 13, 2017, 07:36:36 AM »

I have put 45K plus miles on several Fullsac head pipes with out issue.

HighOnHD · « **Reply #2 on:** November 13, 2017, 10:05:06 AM »

Quote from: danner55 on November 12, 2017, 12:16:55 PM

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!

ultrarider123 · « **Reply #3 on:** November 13, 2017, 10:16:46 AM »

Quote from: danner55 on November 12, 2017, 12:16:55 PM

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

I'm guessing he was very quick to offer help/assistance/corrective action for this issue, however....

danner55 · « **Reply #4 on:** November 13, 2017, 10:53:54 AM »

This failure is not because of a new installation. It been on the bike for over 6 years & 40K miles. Their should never have been a failure like this as it could have turned into more serious condition than it did! I urge anyone that has an older Fullsac header to take the heat shield off & inspect it. It may well worth your time to inspect it!

He said he will give me a 15% discount on a new DX pipe. I will order a new X pipe as it is tuned with this header. After looking at his pic of the header on their website it looks like their is a support bracket welded in the area of the failure with my header. I will only order one if it has the support bracket on the pipe.

Fullsac has always been great with any support that I needed!

Dan

danner55 · « **Reply #5 on:** November 13, 2017, 11:24:25 AM »

Just talked to Steve & we talked about the failure. The new pipes are thicker than the older ones & it does have the support bracket that the older one didn't have.

I ordered a new header & it does have the support bracket!

Steve & Fullsac do treat their customers right! Thanks!

Dan

HOGMIKE · « **Reply #6 on:** November 13, 2017, 05:07:24 PM »

Quote from: danner55 on November 13, 2017, 11:24:25 AM

Just talked to Steve & we talked about the failure. The new pipes are thicker than the older ones & it does have the support bracket that the older one didn't have.

I ordered a new header & it does have the support bracket!

Steve & Fullsac do treat their customers right! Thanks!

Dan

There ya go!!

I am still using my old cx header I bought for my 2010 limited. This pipe has many miles on it being swapped to my last 3 bikes.
It is still giving great service to my 2016 cvo
It looks a little rough, but when ever I remove it it gets a fresh coat of BBQ paint.

I talked to Steve a couple of weeks ago and he suggested to replace it with a new pipe when I do my 117 upgrade!
Looks like my old pipe will decorate the rafters soon!
👍

dayne66 · « **Reply #7 on:** November 13, 2017, 05:15:16 PM »

Almost the same failure on my S&S headpipe. S&S had gone to a thinner walled tube.....had a few failures and went back to the thicker tubing. Mine was replaced (and originally installed and tuned) at Steve Drane HD in Victoria, BC without charge at about 15,000km.

unaharlista · « **Reply #8 on:** November 29, 2017, 08:30:20 AM »

Quote from: danner55 on November 13, 2017, 11:24:25 AM

I ordered a new header & it does have the support bracket!

Steve & Fullsac do treat their customers right! Thanks!

Dan

I hope you received a substantial discount ... or was it covered under warranty?

danner55 · « **Reply #9 on:** November 29, 2017, 10:01:38 AM »

The header was 6 years old & had no warranty! Steve gave me a good discount towards the purchase of a new one.

The new header is improved as it has a gusset between both pipes. I see no reason for this one to ever break apart!

Fullsac comes through again.

unaharlista · « **Reply #10 on:** November 29, 2017, 10:32:37 AM »

Quote from: danner55 on November 29, 2017, 10:01:38 AM

The header was 6 years old & had no warranty! Steve gave me a good discount towards the purchase of a new one.

The new header is improved as it has a gusset between both pipes. I see no reason for this one to ever break apart!

Fullsac comes through again.

Awesome! That's good news!

bluegoose · « **Reply #11 on:** November 29, 2017, 12:51:56 PM »

Dan

Thanks for the info greatly appreciated. I need to inspect mine.

I have 75K on a Fullsac X pipe I installed back in Feb of 2010.

Would never have thought to inspect it if not for your post.

I will report back if I find any issues.

JCZ · « **Reply #12 on:** November 29, 2017, 04:40:45 PM »

Danner you didn't notice a difference in the sound/tone or coming from a different direction before it broke all the way? Just curious if it started with a crack and grew progressively on your ride?

danner55 · « **Reply #13 on:** November 30, 2017, 05:13:36 PM »

JCZ,

Left Woodlands Tx. that morning & after entering Mississippi on I10 the noise from the broken header opened up the VOX on our headsets. That's when I knew had a problem. I was lucky to get to a truck stop where it got welded on the outside. The next day we rode 500 miles to Florida. The exhaust sounded like there was no crack on the back side of the header.

Danner

zigzag930 · « **Reply #14 on:** November 30, 2017, 07:50:43 PM »

Interestingly, this is the sole reason I went with the FuelMoto 2-1-2 Stainless pipe. Lifetime warranty.

I think both products are probably very similar in performance, but considering similar price - warranty was the clincher.

I don't run Fulsac, but if I did - I'd raise the price of the pipe by $15 bucks or whatever and make lifetime warranty standard.

I would not have been happy with the resolution that was offered, but that's just me.

FLSTFI Dave · « **Reply #15 on:** December 01, 2017, 09:42:22 AM »

Quote from: zigzag930 on November 30, 2017, 07:50:43 PM

Interestingly, this is the sole reason I went with the FuelMoto 2-1-2 Stainless pipe. Lifetime warranty.

I think both products are probably very similar in performance, but considering similar price - warranty was the clincher.

I don't run Fulsac, but if I did - I'd raise the price of the pipe by $15 bucks or whatever and make lifetime warranty standard.

I would not have been happy with the resolution that was offered, but that's just me.

I run the Fullsac because its a great product and not rushed to market. Look at M8 dyno runs with the nothing but a fuel moto set up, being head pipe, muffler and tune. Then compare it to dyno runs on M8 with the fullsac head pipe, fullsac 2.0 baffles and tune. The torque curve and bigger torque increase is why I run fullsac.

I would have been very happy with that resolution for a product that does not have life time warranty.

I have had nothing but great customer service from Fullsac.

zigzag930 · « **Reply #16 on:** December 01, 2017, 11:42:32 AM »

I was just sharing my thoughts on the importance of the warranty in my decision to purchase. I'm sure others may have similar feeling about that same issue, so that may be costing Fullsac to lose some business.

As far as the dyno runs, they need to be considered in the correct light. I really doubt that any bikes under 120cu in with basic stage 1,2, 3 or even 4 will see a difference in performance between these two (FM vs Fulsac) head pipes, IF they are both set up by the same tuner, on the same Dyno, using (other than pipe) exact same components.

FLSTFI Dave · « **Reply #17 on:** December 02, 2017, 09:00:11 AM »

Well, I am basing my statement on what I have seen, and what some very well know tuners are saying. Exhaust makes a big difference on torque curve, where the curve starts and both Peak HP and Peak torque.

Heck, just the difference between a 2.0 and a 2.25 baffle is noticeable on the dyno.

Most people run way to big a baffle for anything under 130 ci and 150 torque.

Dacuda · « **Reply #18 on:** January 21, 2018, 10:36:14 PM »

Just had the same thing happen on my 2013 CVO Road Glide Custom, going to call Steve at Fullsac and see what he can do for me

Dacuda · « **Reply #19 on:** January 21, 2018, 10:37:25 PM »

Another shot

DesertHOG · « **Reply #20 on:** January 21, 2018, 11:33:08 PM »

Quote from: Dacuda on January 21, 2018, 10:37:25 PM

Another shot

Breaking at the weld joint is one thing but for the whole pipe to just crack is another matter. Seems like a lot of stress from vibration building up and doing damage. Perhaps the heat from the exhaust changed the characteristics of the metal. I'm no metallurgist but my father was a union welder. The weld itself doesn't look like it flows under the metal of the brace at the joint between the pipe and the brace.

I have confidence Steve will investigate now that there's a second documented field failure.

DH

unaharlista · « **Reply #21 on:** January 22, 2018, 08:15:06 AM »

Quote from: Dacuda on January 21, 2018, 10:36:14 PM

Just had the same thing happen on my 2013 CVO Road Glide Custom, going to call Steve at Fullsac and see what he can do for me

WOW!
How long did you have the pipe before this happened?

Dacuda · « **Reply #22 on:** January 22, 2018, 12:45:15 PM »

Good news just talked to Steve at Fullsac and he is helping me out, again there is only a one year warranty like all manufactures but he is helping me out with a discount, again helping out his customers with great service. New pipe ordered

danner55 · « **Reply #23 on:** January 22, 2018, 02:57:38 PM »

I wouldn't have thought that your pipe would have broke! Yours has a support bracket, mine did not. My new one has a support bracket. I hope I won't have any problems with it. Steve did give me a 20% discount on a new pipe

harleytacticalnut · « **Reply #24 on:** January 22, 2018, 07:59:07 PM »

IDK. Not trying to start a frenzy here but I just don’t feel right if someone admits to using thin wall tubing and then the exhaust fails. For what bases other than cost.
Then the product fails several years later because of the inferior product and let me offer you another upgraded one for a discount.
“The get me once shame on you get me twice shame on me deal”
Am I missing something here. I have been a small business owner for 18 years and couldn’t imagine me treating my customers like that. when I design and manufacturer a part myself that fails like that and then charge them again for my faults. I wouldn’t be around very long. But maybe that’s just me.
I have been riding bikes for 40 years and never had any exhaust break on me let alone to that extent. Even though anything mechanical can happen.
I do agree that is the main reason I have Fuel Moto headers on a few other bikes I have. For what these headers cost either company. They should come with a limited lifetime warranty. Never owned a fullsac cause Fuel Moto has always been on top of their game, so no need to source out to someone else.
But I also wouldn’t be happy about having to buy another header after only 6 years of riding. Discount or not.
But again that’s why we live in the great country so that we are free to make those choices.

dayne66 · « **Reply #25 on:** January 22, 2018, 08:04:34 PM »

Quote from: dayne66 on November 13, 2017, 05:15:16 PM

Almost the same failure on my S&S headpipe. S&S had gone to a thinner walled tube.....had a few failures and went back to the thicker tubing. Mine was replaced (and originally installed and tuned) at Steve Drane HD in Victoria, BC without charge at about 15,000km.

.....and a few months past the one year warranty.

harleytacticalnut · « **Reply #26 on:** January 22, 2018, 08:12:41 PM »

Quote from: dayne66 on January 22, 2018, 08:04:34 PM

.....and a few months past the one year warranty.

Was this on a m8 bike?
Got one coming for 18 CVO Road Glide

Chains · « **Reply #27 on:** January 22, 2018, 08:48:31 PM »

Been following this and was wondering if anyone remembers when Harley had an issue with their rear pipe on EVO dressers breaking into two pieces. I had it happen to two of them and got zilch from Harley no discount not even we will check into it. Happened on my 1995 and 1996.

Glad to see Steve is leaps and bounds ahead of Harley.

robinswl · « **Reply #28 on:** October 01, 2018, 02:36:32 PM »

I have a Fullsac DX-Pipe on my 2014 CVO Ultra. Pulled the shields off to inspect the pipes and this is what I found. I can only show one picture so I can only show one crack, but I have a crack on the rear pipe just before the crossover and a second on the left pipe just after the crossover. Can I repair these cracks by welding, or should I get new headers? I sent Fullsac an e-mail but haven’t heard anything back yet. I was getting the bike ready for a trip across Texas but I’m not going anywhere with these pipes!

danner55 · « **Reply #29 on:** October 01, 2018, 05:26:10 PM »

You can try and get it welded. I tried it myself and couldn't get it done right. Ceramic coating caused a problem. Maybe take it off & find a good weld shop. Hard to believe that yours broke apart with the Xtra support, mine didn't have that. Fulsac gave me a 20%discount but still expensive. I stayed with Fulsac because I did want to tune it again. If my new one breaks apart I will look elsewhere or if I get a new bike which I doubt I will, I'll consider a different company to get one from. Good luck I'd call Fulsac & talk to them.

Sent from my XT1254 using Tapatalk

KGB · « **Reply #30 on:** October 01, 2018, 07:59:13 PM »

Quote from: robinswl on October 01, 2018, 02:36:32 PM

I have a Fullsac DX-Pipe on my 2014 CVO Ultra. Pulled the shields off to inspect the pipes and this is what I found. I can only show one picture so I can only show one crack, but I have a crack on the rear pipe just before the crossover and a second on the left pipe just after the crossover. Can I repair these cracks by welding, or should I get new headers? I sent Fullsac an e-mail but haven’t heard anything back yet. I was getting the bike ready for a trip across Texas but I’m not going anywhere with these pipes!

I had my Rinehart Slimline Duals header crack, just got done installing the new one tonight that Rinehart sent me today under warranty

Sent from my iPhone using Tapatalk

Cat Eye · « **Reply #31 on:** October 01, 2018, 10:03:31 PM »

Quote from: Serdvd6 on October 01, 2018, 07:59:13 PM

I had my Rinehart Slimline Duals header crack, just got done installing the new one tonight that Rinehart sent me today under warranty

Sent from my iPhone using Tapatalk

WOW.....those are some nasty cracks!

KGB · « **Reply #32 on:** October 01, 2018, 10:05:30 PM »

Quote from: Cat Eye on October 01, 2018, 10:03:31 PM

WOW.....those are some nasty cracks!

Trying to catch you on the turns

Sent from my iPhone using Tapatalk

robinswl · « **Reply #33 on:** October 01, 2018, 11:40:36 PM »

Spoke with Steve. Sent him some pictures and he thinks the cracks could be TIG welded. He speculated that the crossover bracket failed and caused the stress fractures. Sure enough, the bolt attaching the crossover pipe to the frame had fallen out. He offered me a discount on a replacement pipe if I can’t get the one I have repaired. Hopefully I can find a good welder.

Thanks for the feedback!

OBB · « **Reply #34 on:** October 02, 2018, 06:31:58 AM »

Quote from: Serdvd6 on October 01, 2018, 07:59:13 PM

I had my Rinehart Slimline Duals header crack, just got done installing the new one tonight that Rinehart sent me today under warranty

Sent from my iPhone using Tapatalk

Must be why I was calling them RineBarks when riding with ya.

unaharlista · « **Reply #35 on:** October 02, 2018, 08:27:32 AM »

Wow! This thread update is not good news!

I recently purchased a DX pipe from Fullsac; bike ran really nice the whole spring/summer!
But now, I think I should go inspect my pipe before the warranty wears out!

JC · « **Reply #36 on:** October 02, 2018, 10:42:46 AM »

Quote from: Chains on January 22, 2018, 08:48:31 PM

Been following this and was wondering if anyone remembers when Harley had an issue with their rear pipe on EVO dressers breaking into two pieces. I had it happen to two of them and got zilch from Harley no discount not even we will check into it. Happened on my 1995 and 1996.

Glad to see Steve is leaps and bounds ahead of Harley.

I remember very well. I must have welded at least 30 of those crossover's.

HOGMIKE · « **Reply #37 on:** October 02, 2018, 02:22:16 PM »

Just a reminder to those who install new/replacement headers and mufflers to tighten the fasteners according to the manufacturers sequence.
Be very careful not to get anything in a bind.

This can contribute to stress cracking as in the early y pipes that was mentioned earlier.
Check tightness after a few miles.
I’ve been using Fulsac systems on my 1995 up to my 2018 with only one crack that was my bad.
Steve made it right for me and that’s one of the reasons I’m still a customer.
JMHO

longlast · « **Reply #38 on:** October 02, 2018, 07:37:14 PM »

It was mentioned about the support bracket that fasens to the top of the trans . I hadn't noticed that the tab that supports the pipe was broken on mine but couldn't see that it was, I only came across it when doing other work and had to remove the exhaust so the only support for the left side exhaust was at the head flange studs and at the rear of the muffler.
I was lucky nothing gave way .
It's a good idea to keep a check all the brackets, if the pipes can move something along the line will fail.

Fullsac Performance · « **Reply #39 on:** October 05, 2018, 10:15:58 AM »

If the OEM style crossover mount on a DX Pipe fails for any reason and the unsupported crossover is forced to carry the load of the left muffler, given enough time the pipe will also fail. For over two years the DX Pipes have been shipped with this new mount that abandons the stock crossover hanger completely. The new mount stabilizes the crossover tremendously over the OEM style. Anyone running the OEM style mount on an older DX should consider upgrading.

Steve@fullsac.com

DesertHOG · « **Reply #40 on:** October 05, 2018, 06:29:09 PM »

Quote from: Fullsac Performance on October 05, 2018, 10:15:58 AM

If the OEM style crossover mount on a DX Pipe fails for any reason and the unsupported crossover is forced to carry the load of the left muffler, given enough time the pipe will also fail. For over two years the DX Pipes have been shipped with this new mount that abandons the stock crossover hanger completely. The new mount stabilizes the crossover tremendously over the OEM style. Anyone running the OEM style mount on an older DX should consider upgrading.

Steve@fullsac.com

Interestingly, my mechanic said, "I really like that mount that came with the header pipe." Now I know why.

Simon

Author Topic: Fullsac Header breaks apart! Anyone have this problem? (Read 10915 times)

ultrarider123