Leak, Leak - Where is that leak?

It was just another typical Friday afternoon in June-uary. It's nearly the end of the day and my gut says the exhaust leak on this 92 Maxima is not the headpipe gasket.

Talked to the customer, told him I want to remove the complete head pipe and look for cracks. You see I used my smoke machine to source out any and all exhaust leaks. What didn't make sense though was the way the smoke curled out below the flange on the head pipe. One would assume it was the manifold or gasket, but my gut feelings said to look deeper.

I removed the pipe, ground off the welds on heatshield and look at what I found. Apparently one of the welds popped off and this WAS the exhaust leak.

These pipes are made out of "want to be" stainless steel. So, come Monday I will run a test pass on a nonimportant area of the head pipe with a mig welder. After that it gets reassembled, resealed and goes down the road. This should make Mike the customer happy!

Here's a picture;