Originally posted by dubkatz:
My question is regards to the mild steel. How long is mild steel gonna last? Ive heard horrer stories about turbo headers cracking after a few thousand miles of driving.



The stories are probably exagerated. Stainless steel headers are in danger of cracking due to the higher coeficient of expansion hence the many returned sets of headers. Mild steel expansion and contraction is easily controlled with slotting around bolt holes and bracing. The liability of mild steel is rust and high temperature breakdown. Stainless steel solves both of those problems but at the expense of expansion and cracking.
Still, all the pipes I had used mild steel and 6-7,000 miles didn't seem to do anything to them. Of course I planned ahead for some of that. If you live out west or southwest I wouldn't worry about mild steel. If you live in the east the road and salt in winter and heavy rainy seasons are going to rust the hell out of the pipes. A good coating inside and out would be a good idea, sort of what MSDS does. This will probably make them last several years or even the life of the car depending upon driving habits.
Keep everything as cool as possible though.
For $3750 for everything but the intercooler you guys are going to be doing pretty good! You can always get replacement piping if something starts to go bad in 3-5 years and it wouldn't cost all that much. For the most part you could consider it the maintenance cost of having such a powerfull car.

Tom

Former owner of '99 CSVT - Silver #222/2760 356/334 wHP/TQ at 10psi on pump gas! See My Mods '05 Volvo S40 Turbo 5 AWD with 6spd, Passion Red '06 Mazda5 Touring, 5spd,MTX, Black