Has anyone had to replaced their 35 Lightning's 525 stock headers. Is this a problem with the pre 2007 (side by side) Lightnings, specifically 2005? I just read an earlier thread in the Technical section recommending annual leak checks and early header replacement. If so what is a good replacement make and how many hours is typical before replacing those used in fresh water only?

I have the same setup myself. From what I have read/been told all of the 525 headers are susceptible to leaks. There are factors that make the chances of it happening better. Staggered and salt water are the biggest. The older style headers are worse which are the non cooling collar ones. The switch to the cooling collars was in late 2005/ early 2006. I have the older style myself. I have had my boat for almost two years and haven't messed with my headers. I have 225 hours on my boat. When I freshen the motors I will have them pressure tested. There are a few options out there for replacements.