any ideas?

Alternative as in a new item at a lower cost than the dealer item.

 

What happened? Also, try ebay or junkyards.

 

Perhaps find a local shop that is competent to build you custom headers. I'm sure that the custom built headers will be cheaper that OEM manifold bought at a dealership, and will yiled higher performance than a manifold. The only draw back will be that if they use cheap or thin metal, you may get cracking. I would find a shop with a good reputation and express your concerns about cracking and ask about quality/thickness of metal and if they will gaurantee their headers.

I am thinking about getting custom headers built myself in the future.

Here is an online shop that will make custom headers if you cant find one in your area...

http://www.stainlessheaders.com/customheaders

 

Interesting company, I like how they go about designing custom headers with out the car.

I'm looking to save money and end up with a new exhaust manifold or header.

 

Guys the header thing has already been answered. There was a set floating around and they were finally installed on a Lincoln LS after going thru about 5 different people. They were about $1500.

The guy that installed them swore he would never do it again. A very tough job!

Do a forum search and you will find all the threads with pictures of the headers. They were very nicely made and it's a shame they did not sell.

This is who made them. They no longer list them because there was no demand. I am sure a call to the people below will flesh out the entire sad story.

Stainless Works Performance Headers & Exhausts
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Ditto...

 

Recently replaced the passenger exhaust manifold with a used unit from Euro Chop Shop (California?) $140. Had it machined ($100). The heat shield is often destroyed during whilst the mechanic disassembles the old manifold, so if you need a very good condition passenger side heat shield ($25).

 

When an exhaust manifold cracks on the STR does it tend to happen to the passenger side more often?

Could any one post if you have had exhaust manifold issues and if so what side?

 

Whats the exhaust manifold made of, cast-iron? Is there pre-cats directly integrated into the STR exhaust manifold?

Cast-iron cracks can always be welded shut again.

 

It is cast iron and the cat is not apart of it.

I can hear a small exhaust leak only under load so its not easy to find when your under the hood so I'm hoping to find out if there is a common side that tends to fail so I have a better idea where to look

 

I expect cast iron. No pre-cats on these cars.