I notice what I think is a tiny hole in the "crotch" where all the tubes join. Could just be an inconsistency in the 2 weld beads, dunno, but I thought I heard a small leak and that's why I checked. It looks like a hole though, so is thee any way to fix it without compromising the thermal integrity of the surrounding metal?? Someone said JB Weld but that stuff's only good to 450-500 degrees. Any suggestions or tips would be awesome!
I plan on getting a Gibson or Borla later, but my wallet says to buy time wit the old one for at least 6 months, maybe a year if possible(skids and hooks first!)

????

If you find a good welder, they may be able to spot weld it while it's on the vehicle.

I was hopin' someone would say that!! LOL

P.S. anypne know a good welder in Portland?(haha!)
Thanks Fred

THere is an info-merical on tv and its an aluminum rod that claims that it will adhere to any material for repair... (metal, copper, tin, iron etc) and it is cheap enough but I can't think of the name of it... I will do some research and post it... and all you need is a propane torch

I'm gonna go over it with a stethoscope when my bro brings it in a few, and figure this out for good. No welder will do it. They all said it would just make things worse. WTF! I wish I payed more attention in shop(haha)
Any other thoughts??? being broke sucks; Can't wait to afford a banks or borla! Just trying to buy some time

Right where I thought it was! Between the two tubes above the flange there is a tiny hole. Igot al lest 3-6 months before it's real bad. I wanna patch it since noone will weld it so I fot this stuff called "Exhaust system repair kit" by Victor. It's like a tape/fabric that you dip in a chemical, wrap around the joint and hole and then run the engine to cure it. Like a putty/Bandaid
OR
Stuff called "exhaust system loint and crack sealer" by VersaChem. More like a putty.

The first at baxter's the second at NAPA.
The guy at baxter's said he's used it b4 and it worked.
The guy at NAPA said"it should work"
I'm on a fence here!! Any suggestions?? Can't find thermosteel. Is one of these comparable??

since it's such a small crack, there's no need to use a 'screen' or 'wrap'. you should be able to get thermosteel at any advance auto store. go in, explain it, and go.
OR go down to the scrap-yard and pull off a 'newish' one. buy a gasket and viola!

OR...leave it ...until you get the Borla header...

^^^well SURE! there's that too! LOL^^^ It won't hurt anything... for now.

Ggot a limited set of tools. Ya think I shoulkd try m hand at doin' this myself or pay someone in a shop. I'd like to try it but don't wanna fuck my car up either, ya know, the whole in and out comin' off.

-If you're talking about a patch with thermosteel or something, sure.
-If putting in a new header, it takes a little planning. Think it through and then make a desicion.
-There are several write-ups on how to do it.

Look here: http://www.naxja.org/forum/showthread.php?t=95384

Thanks for the link citizen. LOL
Gonna think a while about dion' it myself. Time and all.

Sure, you're more than welcome! :smokin: As far as time is concerned, I totally half-assed the planning stages and still got it done in around 5 hours in my buddy's dinky garage/shack. :grinyes: 1st attempt ever? Yup!!!

Check this out... http://www.autopn.com/store/pc/viewPrd.asp?idproduct=20009
"COMPARE ours at half the price of a Banks Jeep Manifold ."

Install: http://www.naxja.org/forum/showthread.php?t=93378&highlight=apn+header

I was lookin' at that one. seems like everyone's pretty happy with it. Only concern is where I would find a grinder if I needed to make the intake flange seat.

pawn shop

If you have the money it probably worth it just to purchase a new to avoid headaches later on

From what I have read in many posts, this is a comon problem with the 4.0 H.O. Apparently it is a design flaw. Mine is leaking now (95' Cherokee Sport with 189k miles), and where it is cracked, I wouldn't attempt to reweld it. And I can weld. 32 years Industrial Maintenance. Just saving my money for a good header system.

Yep...design flaw...

However, with your welding experience, I am sure you could do a fab by adding a piece of metal on top to cover the leak and fill it in. Let us know how that goes.

After looking around A LOT of info for a replacement header on my '98, I settled on Pace Setter's design. In my sig I say they're a PITA, but that's only b/c I have no welding exp. whatsoever...
For the overall design approach, and cost, I'll be getting them again when the time comes. Unless I figure out how to drop a hemi in this thing by then! LOL

SUGGESTION: Do what you must - get a second (or third) job, sell one of your kids, sell your wife's honda - what ever you have to do to get a tuned header on that XJ! You won't be able to sleep at night, you'll suffer from all sorts of undue stress until you do! Nothing bad can come from fixing this right. :evillol:

Here's the one I put in mine when that same crack/hole showed up...

http://cgi.ebay.com/ebaymotors/1996-97-98-99-JEEP-WRANGLER-CHEROKEE-4-0-EXHAUST-HEADER_W0QQcmdZViewItemQQcategoryZ33631QQihZ001QQi temZ110118077271QQrdZ1QQsspagenameZWDVW

Love mine... and I sleep great now knowing that my exhaust doesn't have to push its way through that crappy stock manifold thing.

^^^ Yep, that's the Banks knock-off/APN header right there... ^^^

I'd still rather pay $147.84 total though... - http://www.autopn.com/store/pc/viewPrd.asp?idproduct=20009
Rather than $199... (Both w/S&H added in)

Hey..Citizen..good to see you are reading NAXJA...

Because I've GOT TO mister!!! xD