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Leaking Doug Thorley Headers. What to do?

29750 Views 194 Replies 41 Participants Last post by  JauntyBishop
I bought a set of stainless ceramic coated DT headers in April. I installed them and I thought everythig was ok. In May I bought the uprev and did the logs so i could get my first map tuned. It turned out It looked looked like I had a leak on the left bank, So I took it back apart figuring I had messed something up when I installed it. Once I had it apart I could see the leaks and it was pretty clear why.

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So I called Nick at DT and told him what was going on and he said he wanted to get the header back so they could "fix" it. The problem with this is I live in Florida and its going to take 5 days for it to get to him, then they are going to have to fix it, then its 5 days back and I cant be without my truck for two to three weeks. So we agreed that they would get me a new one but they didnt have anymore so it would be about 5 weeks but he wanted me to call back after 2 weeks and see how things were going. I called again after 2 and a half weeks to check on things and Nick tiold me they were in welding and I should call again in a week and a half. So today I called and he tells me that he was wrong the that the headers being made now are the mild steel not the stainless and he still thinks I should send the one I have to him to have it fixed. I got really pissed because I paid alot for the headers and I just want them not to leak. I cant even get my e-tunes done because of the leak. Another problem is that it sounds like ****.
In his defense its only been 4 weeks so its not like its gone on longer then we agreed but today he didn't even give me a time frame for when I would get them.

I am asking you guys what you think I should do and am I wrong for being upset?
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I see what your saying but Nick is the only person you can speak to at DT. Frank is gone and the president of the company is the only one besides Nick (This is what I was told)
I would be asking to talk to Nick's superior if he is being a problem, regardless of who that superior is. It may take directing that superior to this thread to show him that there is lots of unrest in our community due to a mistake on their part and an apparent lack of interest in correcting that mistake.
wow guys i feel bad for you and those dt headers. i hope u get ur cash back. those round ports are NOT MEANT FOR OVAL PORTS!!!! THERES NO WAY U CAN JAM THE EXHAUST FLOW OUT OF AN OVAL HOLE INTO A ROUND HOLE. such a shame for us titan guys if the chevy guys had this problem they would have had their headers fixed in a 2 day turnaround and all he!! would have broken loose on their forums! this shows how much we stand in the full size truck industry. WE PAY FOR OVERPRICED PARTS JUST BECAUSE ITS AN IMPORT AND GET RAMMED IN THE A55 BY *HITTY QUALITY AND CUSTOMER SERVICE!!! rant aint over!!!!
bj2007, the ports that are in the problem headers are larger than the stock titan ports. If anything they flow better. But, the gasket sealing surface doesn't match and causes leaks.
bj2007, the ports that are in the problem headers are larger than the stock titan ports. If anything they flow better. But, the gasket sealing surface doesn't match and causes leaks.
the headers are useless if they dont seal properly no matter if they are 1 5/8, 1 3/4, 1 7/8 runners! itll cause skewed 02 sensor readings and throw codes 24/7!
My DTLT's were oval and sealed perfect. They made a bad batch somehow and need to fix the problem which I heard they are doing now.
the headers are useless if they dont seal properly no matter if they are 1 5/8, 1 3/4, 1 7/8 runners! itll cause skewed 02 sensor readings and throw codes 24/7!
That's correct. But, a simple change of gaskets could fix that (and no you shouldn't have to do that!). I'm not taking up for Thorley at all. I'm just responding to what you have said.
Update

I picked up the new QX gasket yesterday. I could tell that the holes for the studs were different and I would have to do some modifying to get it to go on. So I pulled the header off and checked it anyway and it almost went on. They went on the tip of the stud but wouldnt clear the threads, so What I am doing is taking a Dremel and elongateing the holes for the studs. The studs on my truck are set closer to one another then the new QX thats why the holes on my headers are elongated. Here are the pics.

The original gasket on top and the new QX below.


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Moding the holes. look at the top left hole.

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That's correct. But, a simple change of gaskets could fix that (and no you shouldn't have to do that!). I'm not taking up for Thorley at all. I'm just responding to what you have said.
That was tried. It did not work.
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OK well it looks like trying to help somebody out backfired. The set of headers Anthony/losemymind recieved was designed to fit the 2012 QX56 but just so happened they fit the Titan as well. The headers are identical except on the Infiniti 400hp version the ports were more round than oval so the flange shape was modified to no block the port on either variation. His headers were not the best I admit so lilke i told him "I will swap them out but it is going to be a bit". He stressed time being an issue so I informed him that the only option then is to fix his. When online "EXPERTS" get involved and tell people what "THEY WOULD DO" it doesnt help the situation any. The next run will more than likely have the standard Titan oval port shape flange so there will not be any worries about this issue again. Also just an FYI these headers are constructed of 304 stainless steel and ceramic coated inside and out where as my closest competitor still uses 409 and only coats the outside as an upgrade. In closing Anthony you will be handled regardless of "if you think I have them in stock or not" as we try and take care of all our customers.

Thanks

Slick Nick:cool:
My DTLT's were oval and sealed perfect. They made a bad batch somehow and need to fix the problem which I heard they are doing now.
I don't think it was a bad batch. I think it was DT trying to use one set of headers for multiple vehicles.
I don't think it was a bad batch. I think it was DT trying to use one set of headers for multiple vehicles.
Thats what we call, cutting cost by reducing R&D and see how many folks would bark before being caught.

DT has not been back on this thread. One can only wonder why.
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That's correct. But, a simple change of gaskets could fix that (and no you shouldn't have to do that!). I'm not taking up for Thorley at all. I'm just responding to what you have said.
have u seen the pictures on here????? no not even with a gasket change it will still leak u cannot make a round exhaust hold seal to an oval exhaust port THERE IS NO WAY YOU WILL STILL HAVE AN EXHAUST LEAK.
Correct you both are. I forgot that at the top of the ports that there is not much meat beyond the port to seal that portion of the gasket. My bad. Thorley didn't make a "bad" batch. But, they did change a part number for a short time and it is being changed back so that there are two separate PN's for the QX56 and the Titans for the stainless headers. The carbon steel headers have always been two separate part numbers.

Again, I am not taking up for them if they are truly at fault for not standing by their product(none of us know the specifics of why no one has gotten back on this thread or why they haven't responded further to the OP's problem, we are merely speculating at this point). I am merely relaying information.

Maybe this thread needs to be forwarded to Thorley by a bunch of our members and that will get a response?
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Correct you both are. I forgot that at the top of the ports that there is not much meat beyond the port to seal that portion of the gasket. My bad. Thorley didn't make a "bad" batch. But, they did change a part number for a short time and it is being changed back so that there are two separate PN's for the QX56 and the Titans for the stainless headers. The carbon steel headers have always been two separate part numbers.

Again, I am not taking up for them if they are truly at fault for not standing by their product(none of us know the specifics of why no one has gotten back on this thread or why they haven't responded further to the OP's problem, we are merely speculating at this point). I am merely relaying information.

Maybe this thread needs to be forwarded to Thorley by a bunch of our members and that will get a response?
They might be different part numbers but it would seem the headers for the qx56 had no R&D what so ever if all they switched up was the ports.
They might be different part numbers but it would seem the headers for the qx56 had no R&D what so ever if all they switched up was the ports.
Maybe they didn't need it? I guess we would have to ask QX56 folks for some dyno results. Maybe they changed up primary dia's, lengths, y type, collector, and flanges... why would it matter one way or the other if they changed one thing or the whole shebang?

The problem is that they don't fit correctly and that should be fixed. It's not whether or rather when you make a mistake when you are in business, it is how you fix it and Thorley needs to help this guy out. Hopefully someone will do exactly that soon.
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Maybe they didn't need it? I guess we would have to ask QX56 folks for some dyno results. Maybe they changed up primary dia's, lengths, y type, collector, and flanges... why would it matter one way or the other if they changed one thing or the whole shebang?

The problem is that they don't fit correctly and that should be fixed. It's not whether or rather when you make a mistake when you are in business, it is how you fix it and Thorley needs to help this guy out. Hopefully someone will do exactly that soon.
I'm not sure if it would have a dramatic effect or not but I would imagine there is a different flow from coming from the Titan engine and the qx56 engine which is putting out 400hp. Again I am no scientist or Mechanic but I would want some R&D done on what ever I am buying for my specific engine.
Who's gonna buy a set a long tube headers for there 70k dollar qx56, I mean really, it's not like that engine is in anything else.
I will keep everyone updated. I am calling Nick back on the 12th hopefully they will be done. Thats only the 3rd time I have said that about this. Thanks for everyones help. The pictures helped a lot and the support has been great.
LMM, what's the word on the DT's? Did you get any resolution?

L
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^^^Any updates from DT?^^^
Still waiting.........
I was told last Tuesday they would be in any day and that he would call me.
Its awsome I drive my truck and it sounds like it has a rusted out exhaust system. It pisses me off everytime I F*****g drive it. I keep the windows up and the radio turned up so I dont start punching the wheel in a fit of rage. I have been considering buying the a different set to fix the problem and then selling the DT's when I finnaly get my new ones. I spent the money on wheels tho. It looks ok but sounds like ***.


By losemymind56 at 2011-08-29
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:huh::soap::crybaby::flame:WTF:boxing::deadcow:

L
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