In addition the motor mounts check this. I don't have the time to read all the replys, so this may be a dup, but anyway. Those welds don't look poorly done, you may indeed have some kind of a stress problem there. Put each header flange-side down on a very flat sheet of heavy steel and I suspect that you see light somewhere. If it is warped even a little, when you bolt it to the head, you'll you will stress the hell out of those welds. To fix it, have them put on a large belt sander and then bolt them to an old head before welding the cracks. Let them cool and then check the flange again and belt sand again if they're still not flat. While this is not the case in your stituation, it may apply to others. The front side of the engine lids often aloow rain to drip on hot headers. When that happens it can and usually will weaken the header. It will even cause your cermic coating to come off if you have any. I had it happen to the front header we made. I've since install a gutter (for want of a beeter word) and redid my header. No more water on the header. If you get a lot of steam when you start your car on a rainy day, it's happening to you too. Somebody makes one of the things, he's posted here somewhere.

It's hard to tell by the pictures,but I cant see any grooves cut into the brackets.I would say the bozo employee went to lunch came back and forgot what he was doing leaveing out the expansion joint.

Just a little update for everyone. I now have the Sprint headers on the car. I've had them on for a couple of months now with absolutely no problems, and they still look perfect. As for my engine and tranny mounts they are all new. I had a new engine put in 2 years ago and had all that replaced, and im also using poly for the dogbone. I'm just glad to see that a lot of people have seen what i went through and hopefully no one else has to deal with this.

With any mig, tig welding you have to stress releave the weld or it will crack.