**UPDATE** - DT has made right - Buyer Beware - Doug Thorley Headers

[Marfy]

Wow that sucks! ! Before I bought my long tubes I inquired DT to make a one off in full 304 stainless knowing that their flanges and air tubes are mild steel. DT skipped the 304 to save on cost, (primarily labor for mig vs tig welds), and reassured me the flanges and tubes are thoroughly coated. I was willing to pay extra to have the entire set done in 304 stainless and left uncoated, similar to the JBA 304 stainless series for other applications, (same exact parent company Pertronix BTW). Nope. Pertronix not interested.

Based on their claims on how these headers are thoroughly coated, I now have a set of DT long tubes ready to go in, but there are many imperfections in the coating. The air tubes are not coated through and through. So... like my TRD headers for my 3.4L I contacted performance coatings to redo these in 2000 degree satin grey ice. The coating will only last so long however.

Hopefully Pertronix is listening. You guys need to make the entire set out of tig welded 304 stainless. This is an embarrassment you knew was coming.

I had no idea the tubes and flanges weren’t stainless. Super disappointing.

 

[4RunnerAquasport]

Wow that sucks! ! Before I bought my long tubes I inquired DT to make a one off in full 304 stainless knowing that their flanges and air tubes are mild steel. DT skipped the 304 to save on cost, (primarily labor for mig vs tig welds), and reassured me the flanges and tubes are thoroughly coated. I was willing to pay extra to have the entire set done in 304 stainless and left uncoated, similar to the JBA 304 stainless series for other applications, (same exact parent company Pertronix BTW). Nope. Pertronix not interested.

Based on their claims on how these headers are thoroughly coated, I now have a set of DT long tubes ready to go in, but there are many imperfections in the coating. The air tubes are not coated through and through. So... like my TRD headers for my 3.4L I contacted performance coatings to redo these in 2000 degree satin grey ice. The coating will only last so long however.

Hopefully Pertronix is listening. You guys need to make the entire set out of tig welded 304 stainless. This is an embarrassment you knew was coming.

I would rather pay extra and have them last. DT should seriously think about charging more on the next run and do them the right way for both gens. Doesn't effect me because of my TC tower gussets will make install on mine a big PIA. So I won't be putting them on mine anytime soon.
But, yea.......I wonder how much more DT would have to charge to have the Tig welder finish off with good material.

 

[Marfy]

I would rather pay extra and have them last. DT should seriously think about charging more on the next run and do them the right way for both gens. Doesn't effect me because of my TC tower gussets will make install on mine a big PIA. So I won't be putting them on mine anytime soon.
But, yea.......I wonder how much more DT would have to charge to have the Tig welder finish off with good material.

Exactly. Have two grades. Had I known, I wouldn’t have bothered truly. Like these look like dog shit. Not going to happen, but in a perfect world, they would build sets out of all stainless to replace this garbage. I feel like pigs will fly before that happens.

Like I said though, the 5th gens have the same style tubing. I wonder how many other models do as well. This is going to be a nightmare for them. I really hope folks contact them. This is a design flaw fully.

 

[Formidable]

The parent company Pertronix for both Doug Thorley and JBA makes long tubes for the 5th gen ENTIRELY out of 304 stainless. Check out JBA 304 series. Flanges, air tubes, the whole shebang is tig welded together out of 304 stainless... so it’s not that they can’t do it. They choose not to based on cost. Unfortunate.

Pertronix - I told you so... Let’s see what you guys do now. LOL...

Exactly. Have two grades. Had I known, I wouldn’t have bothered truly. Like these look like dog shit. Not going to happen, but in a perfect world, they would build sets out of all stainless to replace this garbage. I feel like pigs will fly before that happens.

Like I said though, the 5th gens have the same style tubing. I wonder how many other models do as well. This is going to be a nightmare for them. I really hope folks contact them. This is a design flaw fully.

 

[4RunnerAquasport]

The parent company Pertronix for both Doug Thorley and JBA makes long tubes for the 5th gen ENTIRELY out of 304 stainless. Check out JBA 304 series. Flanges, air tubes, the whole shebang is tig welded together out of 304 stainless... so it’s not that they can’t do it. They choose not to based on cost. Unfortunate.

Pertronix - I told you so... Let’s see what you guys do now. LOL...

I'll jump on that bandwagon!! Neener neener!!
Corporate 'Murica at it's best.
I don't know how big Pertronix is, but If the labor and material costs are the bean counters beef, which labor usually is cause they can't write it off, then charge accordingly people.
But I'm sure the cost efficiency rating for these projects and possible sales numbers didn't match up in their eyes. So they probably suggested to make them cheaper, sell more, and make more quarterly bottom line. I'm sure the R&D folks told them it wasn't a good idea. Hell the topper of it all is they've pretty much had free marketing from Jason and us on the forums and fb. Jason has been great with me and the Y pipe I bought from him. We've kept a text dialog going for months and he is a Yota fan who really does care about these products and how they are performing.
IDK I hate talking trash without knowing the full story and we have been ASKING for these products but, the bottom line is that corrosion in just a couple years on this critical of a part is not acceptable. Plain and simple......
The funny thing is they put the proof right below the injection tubes with they're own quality headers NOT corroding. Kind of asking for it......

 

[Az4runnin]

This is VERY Disappointing to say the least. People have Begged for something Better than Stock with Quality being #1 Period. Someone needs to make this Right and Not give a Line of B.S. to a Customer that Paid Good Money for your Product. Not Covered Really? Damn.

 

[Marfy]

I have invited the folks I’ve been dealing with DT headers to join the discussion here. We will see what they say.

Also, I won’t just copy paste the email thread (at this point) but ya the first email they sent back to me after I showed them a photo was:

1. “That unfortunately is some heavy build up on the injection tubes and may not be able to completely clean off.”

2. “Per our Warranty policy we cannot send out another set for replacement due to rust. A link to our Warranty policy posted on our website is below for further information.”

Best Performance Headers | Doug Thorley Headers | Best Exhaust systems | Warranty

I am researching now to see what other models have this tubing. What a crock of shit. This is two years! I should have gone stock.

 

[snivilous]

They cost like $800, I would've had no issue paying an extra $100 or whatever to have the whole thing stainless. I just finished installing a set, and granted they're on an 03 with no air tube, but it would be nice to not have the flange rust to shit which is what broke on the stock ones.

 

[Marfy]

Email DT to share your thoughts! It’s garbage. The very least they could do is call out that what you’re buying isn’t fully stainless. Again, this is false advertising. I wonder how many people did not know... maybe I can get a group together.

 

[4RunnerAquasport]

They cost like $800, I would've had no issue paying an extra $100 or whatever to have the whole thing stainless. I just finished installing a set, and granted they're on an 03 with no air tube, but it would be nice to not have the flange rust to shit which is what broke on the stock ones.

I'd pay $800 for a set with good flanges and tubes. Everyone knows power in a Toyota truck ain't cheap.

 

[Marfy]

I'd pay $800 for a set with good flanges and tubes. Everyone knows power in a Toyota truck ain't cheap.

I think most would. It’s also the install. That is why their reply of ‘take off your headers and we will recoat them’ is so infuriating.

 

[Cloud9]

I'll jump on that bandwagon!! Neener neener!!
Corporate 'Murica at it's best.
I don't know how big Pertronix is, but If the labor and material costs are the bean counters beef, which labor usually is cause they can't write it off, then charge accordingly people.
But I'm sure the cost efficiency rating for these projects and possible sales numbers didn't match up in their eyes. So they probably suggested to make them cheaper, sell more, and make more quarterly bottom line. I'm sure the R&D folks told them it wasn't a good idea. Hell the topper of it all is they've pretty much had free marketing from Jason and us on the forums and fb. Jason has been great with me and the Y pipe I bought from him. We've kept a text dialog going for months and he is a Yota fan who really does care about these products and how they are performing.
IDK I hate talking trash without knowing the full story and we have been ASKING for these products but, the bottom line is that corrosion in just a couple years on this critical of a part is not acceptable. Plain and simple......
The funny thing is they put the proof right below the injection tubes with they're own quality headers NOT corroding. Kind of asking for it......

Yep, I remember the original post. Jason worked with DT to get these headers made. They wouldn't even have been made if he didn't get involved. I've called him probably 20 times and he really does care and is a true enthusiast like mentioned above. My truck has now had TWO SETS of factory Toyota headers put on it! The Toyota headers are junk and crack in no time and you're looking at $1,600 from Toyota just for the headers without install. I'm now getting 3.2 more mpg over the stock setup with the new headers when I take trips. I've been through a lot and it's about time someone pays me back lol, with the better gas mileage helping my wallet at the pump!

I have a 3rd gen too with factory headers which are rusted but haven't cracked and don't leak. That truck is over 20 years old! I could care less what my headers look like as long as they don't leak. Toyota made a defective design with the factory headers. I've spent good money TWICE to replace factory POS headers. The facts are these cut my cost in half, give a bunch more power and better gas mileage and my truck is a lot more fun to drive. I see no problem here and I'm relieved. I have a very good technical background and can really add a lot of knowledge to this post on why's and how's but I'm going to stay out of it and tell you all to be happy and relax.

 

[4RunnerAquasport]

[MENTION=116567]Marfy[/MENTION] Oh yea with out a doubt. Header install can be a pain even on an old 50s pick up, let alone an engine bay with no room.

 

[Marfy]

Yep, I remember the original post. Jason worked with DT to get these headers made. They wouldn't even have been made if he didn't get involved. I've called him probably 20 times and he really does care and is a true enthusiast like mentioned above. My truck has now had TWO SETS of factory Toyota headers put on it! The Toyota headers are junk and crack in no time and you're looking at $1,600 from Toyota just for the headers without install. I'm now getting 3.2 more mpg over the stock setup with the new headers when I take trips. I've been through a lot and it's about time someone pays me back lol, with the better gas mileage helping my wallet at the pump!

I have a 3rd gen too with factory headers which are rusted but haven't cracked and don't leak. That truck is over 20 years old! I could care less what my headers look like as long as they don't leak. Toyota made a defective design with the factory headers. I've spent good money TWICE to replace factory POS headers. The facts are these cut my cost in half, give a bunch more power and better gas mileage and my truck is a lot more fun to drive. I see no problem here and I'm relieved. I have a very good technical background and can really add a lot of knowledge to this post on why's and how's but I'm going to stay out of it and tell you all to be happy and relax.

I’m confused by your message of “I see no problem here”. So in your opinion, you think it won’t matter to have to replace these too as they are cheaper? That is serious rust in two years. Those air injection tubes are going to fail.

Clearly you have more cash at your disposal than me as I don’t like having to do things over and over...

 

[ac1617]

Yep, I remember the original post. Jason worked with DT to get these headers made. They wouldn't even have been made if he didn't get involved. I've called him probably 20 times and he really does care and is a true enthusiast like mentioned above. My truck has now had TWO SETS of factory Toyota headers put on it! The Toyota headers are junk and crack in no time and you're looking at $1,600 from Toyota just for the headers without install. I'm now getting 3.2 more mpg over the stock setup with the new headers when I take trips. I've been through a lot and it's about time someone pays me back lol, with the better gas mileage helping my wallet at the pump!

I live up in Canada where they use salt on the roads, my 07 doesn't suffer from cracked OEM manifolds yet. Meanwhile if I pulled the trigger on these headers they would've dissolved within 2 years.

This is such a shame, my driver side cat is failing and I was thinking of buying the longtubes and going completely catless but I guess that's not happening.

 

[Seymore Butts]

So Doug Thorley warranty does not cover this? What the hell IS covered?

If Doug Thorley and Jason say their headers are made of stainless steel, and then sell you this crap that dissolves under your hood, then someone may be commiting fraud.

How did you pay for the headers? Some Visa cards have a surprisingly long dispute period if fraud is involved. Well over a year, sometimes two. Get a copy of your agreement and and check. Some guys here may be able to successfully get a chargeback done by their card issuer if the construction or warranty of these Doug Thorley headers was misrepresented.

 

[Cloud9]

I’m confused by your message of “I see no problem here”. So in your opinion, you think it won’t matter to have to replace these too as they are cheaper? That is serious rust in two years. Those air injection tubes are going to fail.

Clearly you have more cash at your disposal than me as I don’t like having to do things over and over...

You need to re read my reply. I have a 20 year old 3rd gen with factory rusted headers. They don't leak. This doesn't mean anything is going to fail, You are probably east coast and super wheel your truck in heavy mud. A truck that lives on the east coast will never look the same as one from FL, etc. There is no other choice for headers. You buy Toyota and it cracks. These solved your issue and mine. no one else makes a better part since it doesn't exist. You saved over $800 getting these instead of buying Toyota brand headers. Pat yourself on the back. I know hundreds of these have been sold and if this was an issue we would have heard about it since then because the shorties were out way long before these and they also have air injection 05+.

 

[4RunnerAquasport]

I have one of the first production runs with an 03' (produced 12/02) German delivery V8, purchased by the US treasury dept. and then it was imported to the states in 04'.
At over 140K (PO put these 35s on her, so it could be over 150K) miles these factory headers are still sounding great and aren't cracked as far as I can tell.
It makes me wonder if they were, as Jason put it "tweeners", where they used parts off another vehicle in the beginning of the production run.
All I can hope for is they are of better quality than subsequent years.
Do the Lexus versions crack too?

 

[snivilous]

I have one of the first production runs with an 03' (produced 12/02) German delivery V8, purchased by the US treasury dept. and then it was imported to the states in 04'.
At over 140K (PO put these 35s on her, so it could be over 150K) miles these factory headers are still sounding great and aren't cracked as far as I can tell.
It makes me wonder if they were, as Jason put it "tweeners", where they used parts off another vehicle in the beginning of the production run.
All I can hope for is they are of better quality than subsequent years.
Do the Lexus versions crack too?

Idk, my girlfriend's already had the exhaust tick when we bought it at 215k and I took the manifold off and where the driver's front tube mated to the flange was visibly cracked and her truck is stamped as 10/02 so was around the same production date as yours. Course it has a lot more miles than yours.

 

[Marfy]

No re-read required. You’re missing the point completely. Oddly enough, my originals weren’t cracked or leaking when I put these in originally. I bought into the lifetime hype as they were stainless and that mine would eventually break.

You’re argument they factory manifolds are more expensive and subpar so these are better is silly. They are still subpar and DT cut corners by using a combination of steel and stainless steel on their “stainless steel headers”.

You need to re read my reply. I have a 20 year old 3rd gen with factory rusted headers. They don't leak. This doesn't mean anything is going to fail, You are probably east coast and super wheel your truck in heavy mud. A truck that lives on the east coast will never look the same as one from FL, etc. There is no other choice for headers. You buy Toyota and it cracks. These solved your issue and mine. no one else makes a better part since it doesn't exist. You saved over $800 getting these instead of buying Toyota brand headers. Pat yourself on the back. I know hundreds of these have been sold and if this was an issue we would have heard about it since then because the shorties were out way long before these and they also have air injection 05+.