The coating on the inside of my FLP headers has disbonded or otherwise come off. Since the coating has come off, bare mild steel is exposed. Condensation in the exhaust has oxidized the exposed mild steel and rust chunks have begun flaking off and exiting the tail pipes. This happened to my FLP header system.

I started the car two weeks ago and when I looked behind the car there were a lot of rusted metal flakes behind the exhaust tips. At first I thought it was the cats because the inside of the FLP's are supposed to be coated, and the rest of my system is stainless steel. After showing the material that came out of the exhaust to some local experts, we figured out what had happened.

We unbolted the X-pipe to cat-back connection and looked inside the X-pipe. Sure enough, it was rusted like crazy. I am worried now that my header pipes will plug my cats up with rust flakes. I know the car won't run if this happens.

Now you might be thinking, what did FLP say about this. I wish I knew. They seem not to want to return my tuner's phone messages to discuss an appropriate course of action. I bet if I called to place an order, they would call back right away. I only have about 4 or 5 thousand miles on the FLP system and as far as I am concerned, it is junk. I paid a lot for the system and to have it installed, so I hope FLP steps up and does the right thing.

Has anyone else here had a similar experience. If so, what remedy was offered by FLP?

I recommend that you guys with FLP's unbolt one side of your cat-back and check the condition of the inside of your X-pipe. Then, check your header pipes / merge collector.




I wish I had taken some pictures of the rust flakes so you could see the size and quantity.

 

Sorry to hear of your problem.

Its why I went with 304 stainless as opposed to "coated" headers. Most of the headers which come with Jet hot or other coatings are mild steel beneath the coatings. If there is a breech in the coating a nick, chip or scratch, when the mild steel underneath starts to corrode it can be tough to manage.

Hope you get it taken care of and good luck.

 

... Most products have some kinda warrenty for problems like this. However, generally it's just for parts. I think one is better off to get the Stainless Steel and spend their time driving their Vette instead of redoing work.

 

Sorry to hear this. I have only seen the smallest amount of corrosion on mine and that's due mainly to condensation on the rear flanges so it's of no concern. I have seen a few other FLP installations and most had little or no rust or corrosion internally. Mine have been on about 4K miles as well. Below is a recent shot I took looking into the collectors. I hope FLP steps up to the plate and straightens this out.

 

Maybe it's time for you to call FLP rather than letting someone else take care of this, I've had my FLP headers on for over a year and I have since removed and reinstalled them a couple times for other reasons and have had nothing like what your talking about.

Maybe you could also call the people over at Jet-Hot and talk to them about this.Jet-Hot coatings

 

I have had mine (FLP system) on for two years and no problem like your describing. I am very happy with them. Also I had questions for FLP one year after my purchase and they were very responsive.

 

I've had my FLP system for around a year and have had no problems like yours. However, I have had problems finding plug wires that will stay away from the rear driver's side primary tube.

You should get on the phone yourself and talk to FLP. Good luck.

 

I had a set of Magnecore wires on for 18 months. I use the stock heat shields. I pulled the heat shield off of number 7 just to see what would happen. Within 2 weeks it's was misfiring. So I replaced that wire and put the heat shield back on. That was about six months ago (no further problems)

 

FLP should replace the headers. It is not normal.

 

We have FLPs on our every day driver 00' coupe. They perform great but the coating..............well this is what I had posted about back in this thread on 10/21/03:
http://forums.corvetteforum.com/show...lp+heADER+RUST
"I have a little issue with my DS header..............this is NOT FROM THE AC discharge and you can see the scratch marks I touched up prior to firing up after the install. No rust in the scratch marks, but below "

"The PS is fine"

"Usually inproper prep for the coating/thin coating application is the reason for this.
The vendor I bought these from is looking into it.....less than 1 year on an EDD.
I will sand & put some hi-temp on just like the scratches "

I got them from LAPD.......they got with FLP............I went to FLP's shop in Dec 03' while in town and talked to Mitch & Chuck about them, these pictures and the e-mails I had sent them. They were nice enough to show me around the shop & talk shop but.............no resolution or call as of today. They are Airborne coated...........and not as big a deal as a leak or broken collector tab but damn the DS looks like crap and its deep rust!
Good luck, call FLP/vendor you got them from

 

I added a couple of shots of the inside of the X-pipe in the first post. I dialed up FLP, but have not heard back yet.

--Sean

 

My gosh Allthrottle and No Bottle, I sure hope you get this resolved.

 

What a coincidence. I got rust that looks exactly like yours in exactly the same place. Headers have been on for 18 months but only 3000 miles. WTF!