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On the other hand, I have nearly 3000 miles on my wrapped ebay headers - so far so good. I have done my share of towing as well. I live in MA, and it's not uncommon to have a steaming hot day, with random downpours. This creates massive puddles. Nothing like a smoking hot header coming into contact with a cold rain/puddle to test the metal.
It's certainly possible you've got a bad header there. And the crack appears to be on a weld seam - naturally.
I'm sorry to hear of your issue - it sucks for sure.
I'll be keeping a closer eye on mine and reporting my findings as time goes on.
Just a thought, do you have a clogged cat or muffler. I had issues with headers and doughnut gaskets one time when I had a restriction in the exhaust. Of course I was running a roots blower at the time but worth a look.
I don’t suspect a clogged catalytic converter or muffler, I guess it’s possible. The truck runs fantastic and have no reason to suspect a clog. What should I look for?
I have about 3 years on mine, and about only 15K miles I think, but lots of stop-and-go, short trips, lots of stops and starts, high-load pulls (woods, pulling complete trees through the woods in 4x4), some highway miles, etc. etc.
I had a similar experience with some Toyota V6 headers from Downey off road. Nickle plated. I wrapped them like you did. They lasted a few thousand miles and started leaking BAD. When I went to replace them with same thing, and un-wrapped old ones... WOW. Massive corrosion, distorted tubes, cracks from the heat. Very similar to what yours are looking like (just more corrosion). New ones went back on WITHOUT wrap. Never had another problem.
A vote for the BANKS now... Very happy. Made of the more malleable 409 stainless (softer). Not wrapped !
I agree with the Banks headers, they're great. Just couldn't pay the price they (Banks) are asking. Banks offered me a set for 300 bucks off but still couldn't pay that much. Maybe I'll come across a set in the junk yard?