I need to replace a leaky down header pipe for the 89 240 with EGR (California car). It uses the triangular 3 bolt flange at the catalytic converter end. What are your experiences/recommendations for various manufacturers?

So far I have found:
Bosal for $89 at FCP

Is there any other manufacturer/vendor I need to look at?
Thanks for the help
Justin

Justin,
For future reference, Autohaus AZ in Phoenix also carries a variety of Volvo after market parts. I just bought my Bosal 240 header from them for 90 bucks and with any order over $50 they ship free. I got the parts in two days. Faster and cheaper than FCP for Brick owners out in the West. I just received a small box of poly 240 bushings and Mann oil filters from FCP that took a week to arrive and they charged me $15 in shipping/handeling fees!!!

I shop Autohaus AZ when every possible these days.
Check this out ....

http://catalog.autohausaz.com/autohausaz/detailw.jsp?sid=fadrbqib1r310xepdpprk555&partner=autohausaz&year=1989&make=VO&model=240--004&category=H2000&part=Header%20Pipe

Autohaus AZ is just another distributor for WorldPac which means they have the same parts at almost the same prices as another 100 or so online distributors such as
http://alleurasianautoparts.com
http://autotruckpart.com
etc etc etc...
The problem with these guys is when one doesn't have a part in stock, none of them do. I ordered from autotruckparts for $87 and free shipping only to find out then next day that they were out of stock and it would take 6 weeks to get another. So FCP is my next best option.

I took mine off the car and welded it up. I reinforced the hanger area so it would not crack again. The pipes I have seen are fairly overpriced. If you do not have a welder then take it to a near by machine shop. They will more than likly be a heck of a lot cheaper and do a better job than most stock replacements. The three bolt flanges are available from most speed shops if you need them also. I think they are 2 1/2 inch but not really sure. If you were close I would weld them for you but I doubt you live near here. I live in the state of Confussion.
--
Max..1989 244 DL 5 Spd., V15 Phase II Cam Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights and now NEW ECODES with the turn signals, 1992 black 244 next project

Thanks for the advice and offer. I live in Northern California, San Rafael to be exact.
So it turns out the vendor where I ordered the down pipe doesn't have it in stock after emailing me a tracking number. Hmmm, interesting way of doing business. They did send me the proper gaskets though. So I think for lack of a better down pipe, I am going to remove it and have the remaining hole welded up. I'm sure its just another failed weld somewhere near the down pipe to manifold flange. If anyone near by has a welded and is willing to help me out my email is jtantare@gmail.com
Thanks
Justin

The problem I had on most the ones I have repaired is a crack between the two joining pipes near the curve where the mounting flang attaches to the tranny. Some of the cracks are so invisible I had to blow compress air through it to find them. I welded that area between the pipes up solid for about 5 inches towards the mainfold end of the pipe. You can hang a Mack truck on it now..Anyway wish I were close I would be glad to fix it but as I am on the other side of the country I doubt shipping cost would be worth it..Just find a good machine shop or muffler shop, either will be glad to help if you talk to them right. Don't pay over about $30.00 for a weld job. If they have to replace some pipe then it will be more as they usually charge for a complete lenght of pipe and not just what they used.
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Max..1989 244 DL 5 Spd., V15 Phase II Cam Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights and now NEW ECODES with the turn signals, 1992 black 244 next project

I Took off the heat shield where the two down pipes meet where I found the leak right where you describe it. I had a local exhaust shop patch up that leak but the noise didn't go away. It just got quieter. They listened to the whole length of the down pipe very carefully and found another spot that was leaking inside the upper heat shiled. Its drivable now but still somewhat annoying. I finally gave in and ordered a new bosal part from FCP. I'll have it reinforced at a local metal shop and painted with high temp before I install it.
Thanks again for the help
Justin

I just received my down pipe (1989 240) today from FCP. Its a Bosal and it looks like its a fairly well made piece. I also ordered a catalytic converter. Both pieces mate together with a triangle 3 bolt flange. Hopefully I'm done with exhaust system repairs for awhile. I replaced the center and rear muffler last year.

I've used the Bosal on our '93 with good results. Check delivered price from eeuroparts.com and alleurasianautoparts.com. Both of them offer free shipping at a certain order size which can make the delivered cost less than from FCP with shipping, especially for us west coasters.

John

make sure YOU DO NOT buy those stainless steel headers from Ebay, they are complete garbage.. i've seen pics with them totally melted to ish.

FCP is fairly reputable, however i haven't bought an exhaust manifold from em... another idea would be togoto a junker and get a 90+ volvo manifold.

I'm not looking for the manifold. Just the header pipe otherwise known as a down pipe which fits between the manifold and the catalytic converter. I don't want to go the JY route because most of the cars there have many more miles and the exhaust is in far worse shape than mine.