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Thanks to everyone for the responses. When repairing the first two breakages, we DID add metal, maybe just not enough. I'll make an effort to really over-engineer it this time (on the underside so it doesn' t look like hell).
Has anybody seen a gap separating the two broken ends when they do go? As I mentioned earlier, each time my straps have broken, I've had at least a 1/4" gap between the pieces-- hot or cold.
Aeroace-- I live in Detroit, arguable home of America's worst roads (tho I'm sure Afghanistan wins the world title these days). It's just not billiard-table smooth sportscar land around here. No contact between car parts and the ground. And no off roading, I promise! You would think that Motor City, possibly home of the world's greatest concentration of gearheads, would at least have drivable roads.....
Anyway-- anybody seen big gaps (indicating the straps are under tension) when these thing bust? I'm wondering if the source of my problems is improper alignment up front, from my headers.
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