RE: OS 91 Surpass header
There just has to be some vibration that's causing the heavy muffler/manifold assembly to move a bit. That will cause stress right at the engine. You'll need to support the muffler to prevent this from happening. With this large an engine, it's easy to have the manifold stressed. While you may not see much vibration, it's there, and it's causing the muffler to move around.