ThunderHeader - Broken support
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From: Ak-Tenn
ThunderHeader - Broken support
I've got a 97 fxdwg that is a little souped up. I wish I could tell you exactly how..... but the the PO had it done to it and I bought it on consignment without getting the particulars. (Dyno test says 87 hp.) It only had about 5,000 miles on it and I've put another 30,000 or so on in the last 3 years. Twice the support bracket behind my right heel has broken and caused the exhaust studs to snap also. Has anyone else had this problem? If so, what did you do to rectify the situation?
Thanks for any help or suggestions.
Thanks for any help or suggestions.
Road Master
Joined: May 2006
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RE: ThunderHeader - Broken support
I have read others having a issue with it. I do not recall reading any fixes accept some switched something else. All I know is you are not the only one. I have never seen the mounting bracket spoken of but maybe you could talk to a welder and have a gusset welded on for strength?
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RE: ThunderHeader - Broken support
AK97, I have a 2001 WG and have had the same problem, without the broken studs in the head. Mine has the bracket bolting to the trans and a plate for the carriage blots that fit in the slots in the muffler part of the header. I think that the problem is that the header heats up and expands toward the rear of the bike. This puts stress on the bracket which doesn't expand and the damn thing breaks. Mine broke in the same spot yours did. I had the bracket welded and rather than tightening the nuts on the carriage (muffler) bolts I backed the nuts off and added a jam nut to keep the nut in position. Worked fine until I had new tires put on. The shop that did the tire change put the thunderheader on and tightened the nuts up tight. This gave me a vibration that I could feel through the grips at highway speed and drove me nuts until I loosened the nuts and put the jam nuts on again. The bracket is holding up now but I am looking for an Evo bracket as that has a rubber isolator at the end of the bracket so that the muffler is not bolted up solid. Don't bother trying to get through to the manufacturer as they won't answer the phone or return calls. You have to go through a dealer or maybe call Sonny Barger. My dealer never heard of the problem before. Hope this helps.
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Outstanding HDF Member
Joined: Jun 2006
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From: Ak-Tenn
RE: ThunderHeader - Broken support
ORIGINAL: 5701andbroke
AK97, I have a 2001 WG and have had the same problem, without the broken studs in the head. Mine has the bracket bolting to the trans and a plate for the carriage blots that fit in the slots in the muffler part of the header. I think that the problem is that the header heats up and expands toward the rear of the bike. This puts stress on the bracket which doesn't expand and the damn thing breaks. Mine broke in the same spot yours did. I had the bracket welded and rather than tightening the nuts on the carriage (muffler) bolts I backed the nuts off and added a jam nut to keep the nut in position. Worked fine until I had new tires put on. The shop that did the tire change put the thunderheader on and tightened the nuts up tight. This gave me a vibration that I could feel through the grips at highway speed and drove me nuts until I loosened the nuts and put the jam nuts on again. The bracket is holding up now but I am looking for an Evo bracket as that has a rubber isolator at the end of the bracket so that the muffler is not bolted up solid. Don't bother trying to get through to the manufacturer as they won't answer the phone or return calls. You have to go through a dealer or maybe call Sonny Barger. My dealer never heard of the problem before. Hope this helps.
AK97, I have a 2001 WG and have had the same problem, without the broken studs in the head. Mine has the bracket bolting to the trans and a plate for the carriage blots that fit in the slots in the muffler part of the header. I think that the problem is that the header heats up and expands toward the rear of the bike. This puts stress on the bracket which doesn't expand and the damn thing breaks. Mine broke in the same spot yours did. I had the bracket welded and rather than tightening the nuts on the carriage (muffler) bolts I backed the nuts off and added a jam nut to keep the nut in position. Worked fine until I had new tires put on. The shop that did the tire change put the thunderheader on and tightened the nuts up tight. This gave me a vibration that I could feel through the grips at highway speed and drove me nuts until I loosened the nuts and put the jam nuts on again. The bracket is holding up now but I am looking for an Evo bracket as that has a rubber isolator at the end of the bracket so that the muffler is not bolted up solid. Don't bother trying to get through to the manufacturer as they won't answer the phone or return calls. You have to go through a dealer or maybe call Sonny Barger. My dealer never heard of the problem before. Hope this helps.
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Joined: Sep 2005
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RE: ThunderHeader - Broken support
I was in the middle of wrapping the headers on my '01 Dyna T-Sport when I found a broken clamp, (between the headers and the muffler). I just placed some thermal wrap under the clap to help with the vibrations. All's well so far.
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Joined: May 2006
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RE: ThunderHeader - Broken support
AK97, I thought about other headers too but the Thunderheader really gave my bike a boost in torque. I've been told that the Thunderheader and Basini headers are the best for Harleys. It took a while to get used to the sound but I like it now. 2 into 1 headers are supposed to be best for Harleys.
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Road Captain
Joined: Mar 2010
Posts: 563
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From: western Montana
I've had the support bracket break several times on mine,right at the second curve after the trans.I see on thier website,the aded a gusset to the bar,between the curves to beef this up.this is on my 02 Dyna,btw.
http://www.thunderheader.net/parts/html/1180A.html
thinking about finding someone to buy one from,in my case,I let someone weld it once instead of doing it myself,and he got it twisted and screwed up.
http://www.thunderheader.net/parts/html/1180A.html
thinking about finding someone to buy one from,in my case,I let someone weld it once instead of doing it myself,and he got it twisted and screwed up.
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From: hamilton montana
i had a thunderheader on my 99 softail for about 65,000 miles. the mounting bracket broke twice. i beefed it up the second time and it held. the pipe cracked where themount bolts to it. it also cracked at both headpipes where the flange holds it in the head. they sound good make good power but dont seem to hold up if you ride ling distance at speeds of 95 mph and up.