header finally failed the other day after being cracked for a while. was hoping it would hold out till my car was done but it wasnt having it. going to email fmf soon and see if i can get this replaced. just thought some of you would get a kick out of this.

 

Wow. That sucks.

 

...i noticed my fmf megabomb was significantly lighter than my stock header pipe eventhough it's so much bigger....and it looks quite thin too..i guess the weld is weak too....sheesh...

 

Not stepping up for FMF, but incorrect installation of the pipe/header may cause this. It doesn´t mean that a proper installation wouldn´t cause failure, thou.

 

Just doing a Google search showed several hits of the same problem on a string of these pipes. FMF seemed to be addressing warranty on the failures in most cases and attributed it to a "cold weld" problem. It sounded hopeful that they might take care of you in this regard.

 

I did a lot of welding 23 years ago, and cold welding fascinated me...I didn't know that FMF used that process with our pipes. Very tricky stuff, but very cool too. I'd love to see that done in person.

 

I had to have my Megabomb TIG welded after a hairline crack appeared (after 11 months) at the same place as your Powerbomb broke!! They are very thin & light weight.

 

The OEM header is the most durable one available. Anytime you deal with the lighter and higher performance aftermarket exhausts, you will sacrifice durablility to a degree. I had an ultra-badazz, full titanium Nassert exhaust system on my KLX and it eventually failed in that same area...but that was after about 4 years of steady thrashing. The muffler was ready for a complete rework as well, but by that time that entire system had been discontinued...always seems to work that way for me.

 

Hopefully fmf will come thru but it looks like a good welder could put it back, tack it on the bike and pull it off and make it forever.

 

Bolting head pipes and mufflers onto this bike can be a minefield. More things can go wrong than right. Get some help from a smart mechanic or fabricator. You just have to understand the things that can go wrong to be able to do it right. Sounds easy? It can be with a little help.