Can any one explain what can do this ?!

 

Is the header split along the weld line for the collector?

 

yes .. when i remove the header it was split along the weld for the collector .. it was a shock

 

or a failed weld, perhaps. Have you close ups of the broken seam? Hard to tell from pics. Might be re-weldable, if you'd ever trust it again.

 

I dont think that i would trust it any more. I may change the headers with 997 turbo one. my friend is giving me for free

 

looks like poor penetration given the cleanness of the break. I would never trust a wastegate rod where the entire thing was threaded -stress risers everywhere, particularly dicey on portions with bends. Though this one may have been affected by exhaust gas from the cracked header. ..just my .02

 

I saw that happening (on aircraft pneumatic ducts) when the two parts are not aligned properly and stress is always present in the installation until it break....

 

Actually for now when i move the splitted waste gate bolt its little bit sticky specially when i move it all the way to the back.
It may be affected from the cracked headers. i will get more pic and more details when i go back tomorrow to the work shop to check the turbo.

 

That problem with the threaded wastegate rods has been around for some time. The EVOMS rods used to break at the junction of the bend also. I think they fixed that, The OEM rods are solid with no threads except for the ends where the nut attaches for travel adjustment. The UMW wastegate kit uses the original rods and I haven't heard of any problems with that setup. I installed the UMW kit as did ARD. If you buy any wastegate kits with the rods threaded all the way down, you're looking for potential problems. I'm surprised Agency hasn't corrected that given the history of broken rods and extensive archived info on the forums dealing with this exact problem.

 

Is the turbo bolted to the hanger on top? if not do not be surprised... do not expect the header to hold all that weight....
sometimes dyno straps or even towing will split the ehaders as well...


that explains your boost issue you have been telling me about...
I have a nice set of headers if interested...
markski

 

Definitely a lack of penetration. Pretty bad welding or just bad welding procedures and specifications. The material also looks pretty thin.

 

appreciates

 

Thats what i'm expecting

 

The other thing that can cause this relates to the welding procedures or a screw up in manufacturing. Wrong or improper filler metal.

 

So it relate to the manufacture .. mats or welds