Doug Thorley Headers Fitment. Show me your ball Flanges.

That’s simply unacceptable. That’s all you should have to tell them. Ask DT if that’s the kind of reputation they want for themselves. Open a case with PayPal to get your money back, and make them pay return shipping.
Ups lost an old man emu leaf spring out of a shipment. Arb sent me another set, and told me to trash the one I didn’t use. That’s good customer service!

 

Bottom line, I just want them to make this right. A PayPal claim will be my last resort.

 

A number of years ago I was similarly unimpressed with DT Wrangler headers.
For the OP's Tacoma - I take it the TRD header kit is no longer available?

 

TRD headers are long gone, discontinued years ago. Hard to find used too.

 

I think they spray painted the name tag. Looks like everything else has the correct coating, you could probably clean that off with a clorox wipe and some elbow grease. But again you didn't pay for good money to have extra projects and requirements. If you wanted cheap parts you would have payed for cheap parts.

 

shame, seems like the aftermarket ones are all trash.

 

I remember a few years ago there was a bunch of TRD header kits on eBay from one seller - apparently a bunch got discovered in a warehouse and he was selling them for around $700 if I remember right. Of course they went quick though.

 

@Digiratus @vonellis @Shortman5
You all three touched on the2 bolt flanges of the DT's headers and I can't help but to wonder if the 3 bolt flanges on the JBA headers are the way to go

 

Sure. And that isn’t something I haven’t considered. However, brand new out of the box the plate is ceramic coated just like everything else.

Also, within a short period of time I’d assume that plate would be rusted to hell with the heat cycling and humidity levels here. Especially for a spray paint that is so easily damaged by acetone. It won’t last long to environmental extremes

The EGR port that they welded shut seems to have the same looking spray paint. So I just have a theory that they welded the EGR shut and changed the plate with the CARB number after it was “ceramic coated” or maybe it got knocked off and they did what they could.

These smaller issues really stand out when you consider everything so far.

Oh, and I’m still waiting on that call from DT like I was told was going to happen twice now.

 

The flange design won’t do you any good if they aren’t properly aligned.

 

They may not be fully welded. I have JBA knockoffs and the 3 bolt flange on the crossover pipe isn't welded to the pipe to account for alignment issues...

of course the fitment is still trash and they leak.

 

Here’s the driver side welded shut EGR header I was sent. Surface rust showing though less than a week after receiving it. Notice the dull sheen.

 

I looked at the jba kit a while back, pretty sure welding is required to install them….just no. IMO.

 

The way JBA designed the 2 cat kit is that you cut the factory flange off of the cat and stick that tiny 2.25” end into the oval shaped JBA Ypipe.

Purchasing $700 Headers that are supposed to improve flow to just then jam a restriction right into the end of the headers system.

 

To be fair you have to weld on the DT system as well. But they send you a flange to weld to the cat and it does not act as a restriction like the JBA does.

 

When I installed the TRD system, same deal - had to find a guy to weld a flange

 

Sorry to hear all your issues,
Ive had mine on for about 30k,
No issues, no rust,
They bolt right up to the 1997 cat, no welding needed for my year except for the ERG tube for the early supercharger.

 

Beautiful

 

Yeah, same here, no issues with mine either.

FWIW, for anyone considering headers, IMO, DT is still the best option.

There is no evidence that there is any advantage to a 3-bolt flange. It doesn't look like the problems Levi is experiencing are being caused by the flange type DT uses.