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timm3r said:
where do you live? did you ever lower your car? did you ever scrape your headers at all?
The header was never bumped, hit, or curbed. I live in the north east. Well if you want to call it lowered, I have H&R OE's that were put on about the same time.

All the cracks started at the welds. As you can see there is clearly a lack of weld penetration. Though it looks good, there is no penetration into the base metal and it separated and the crack propogated into the base metal.
 

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timm3r said:
north east? like new jersey area? it snows there doesn't it?
It snows here and they use salt too. But the rust is NOT the problem. It's the lack of weld penetration in the unrusted steel that is the problem.
 
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