My HHR has the third exhaust leak.Who can recommend a good header, complete exhaust system that I can actually find?

 

I would be more interested in finding the cause, I never heard of anyone having that sort of problem. Maybe bad motor mounts, they can cause the flex tube to break.

 

Yes, look at the upper motor mount, to check it just look thru the oblong hole in the passenger side inner fender, if the bolt head in there is low in the hole the motor mount is toast!



The bolt should look like this.

the worn mount can cause vibrations that will break the flex pipe as Donbrew states, it can cause failure of the flange gasket also.

 

The OE Exhaust is made outta "aluminized stainless".....

 

My flex pipe is broken as well, the motor mount seems ok but I plan to do a lot of preventative maintenance this spring when the weather breaks, timing chain, water pump, motor mount and I have one of those woven flex pipes to replace the cracked one.
I don't see any advantage to a header on these engines, unless you are planning other mods to improve breathing.

 

If the exhaust manifold has a crack in it, some replace it with a header , but OEM style cast iron manifolds aren’t that expensive!

 

Headers have their own problems on most cars, rusting out, header gasket leaks, etc. I 'm not a fan of them on a daily driver.

 

I'm changing the whole exhaust system for better flow and will be installing an after market intake as well.
I appreciate who ever replied about the motor mount because mine is bad and will be getting replaced.

 

Quality headers today will have a very thick flange & not have the issues like cheap or old school ones had.

 

Yes, but those EBay headers, aren’t quality headers! And for a DD , cast iron manifold is good