Cross over pipe broke away from manifold flange
 

Hi, has anyone seen or come across anyone that has had the cross over pipe break away from the flanges? I was driving today when all of the sudden the exhaust got really loud. I pulled over and saw that the cross over pipe broke away from the driver side flange. Seems like it broke away just past the weld which usually indicates a vibration issue. Only thing is I have poly engine/trans mount and I don't feel any vibration at any rpm. Runs really smooth. I might fix it and over build it with a better bellow, double wall pipe at the flange and add more "gussets". I emailed the vendor to see what he says. Turbo kit is about 5 years old but only put around 1k miles on it. Info- 1995 C1500, 6.0, 76mm turbo
https://cimg9.ibsrv.net/gimg/www.per...84f7162c9a.jpg
https://cimg1.ibsrv.net/gimg/www.per...2b55c989cb.jpg

the exhaust pipe’s weld doesn’t look to have much penetration

Agreed. Looks like it was leaking longer than just when it broke. I broke my stock one just like that, I was experimenting with removing some leaf springs and experienced severe axle hop.

Yea I didnt even know it was leaking before but my exhaust is somewhat loud so it would've been hard to notice. I'm going to fix it myself since I have a tig welder at work. Gonna add more filler at the flanges and put 3 gussets per flange instead of one. Id rather go overboard so that this kinda problem wont happen again.

Looks like a cold weld. Never had an issue with my SS tig welding breaking like that. I can’t see the inside but is there sugaring that can be seen?

Looks like the flange is mild steel. If it is, that adds the possibility of the wrong kind of filler having been used into the mix.

Had a similar breakage on a different application. But my pipe was run through the ringer for 75k miles of daily abuse and had header wrap the entire time. Welded it back together and went racing.

I didnt see any sugaring but penetration was minimal.

Yea the lead tech at my work told me that you have to use 309 filler rod so we'll be using that for both flanges.

309 L
the "L" is important