Exhaust Manifold Flange snapped from Downpipe

[graphikg]

I will post pictures in a little bit, but I cannot believe this happened.

I noticed an exhaust leak and went to replace the gaskets and *clunk* my exhaust dropped when trying to unbolt the exhaust downpipe from the headers. The flange completely broke off the welds of the headers. I will upload pics soon when I am off my work computer.

But what do I do now?

1. Get a muffler shop to reweld the flange on my s52 headers and continue in that manner

OR

2. Get some ebay headers and toss the S52 headers?

Whatever it is, I need the headers to clear my swap and the large diameter sway bar.

[graphikg]

How could this have happened?

[AndrewBird]

If the exhaust was not supported well (IE - torn hangers), the extra movement over time could have caused the welds to crack and finally break. That, combined with rust, and there you go. Re-welding the flange should be easy, though you will have to pull the header off.

[TimKninja]

if your exhaust clears the subframe well now I'd just have it re-welded .the ebay longtube headers are a pain to fit in the car , and it's a hit or miss if their gonna fit allright.

[Mr.SWISS]

if your exhaust clears the subframe well now I'd just have it re-welded .the ebay longtube headers are a pain to fit in the car , and it's a hit or miss if their gonna fit allright.

And I may add you typically will need to have the O2 bungs adjusted to clear the e30 firewall and they are NOT easy to install with the motor in the car, they are nuisance out of the car even...

[nokincy]

if your exhaust clears the subframe well now I'd just have it re-welded .the ebay longtube headers are a pain to fit in the car , and it's a hit or miss if their gonna fit allright.

This. If I could do it over again I would have just used my s52 headers.

[graphikg]

Great insight - I guess I know what to do then. Off the S52 headers go then and to the exhaust shop. Cheaper option as well. Thanks my friends.