exhaust leak question.

[j.rigby15r]

I have a exhaust leak between my header collector and the exhaust pipe in the drivers side. My leak was originally on the passenger side, so I got aluminum gaskets, since my copper coated paper ones failed quick. My driver side was good but like I said my passenger leaked. So I decided to replace both with aluminum ones. The passenger is good and tight, but the drivers is leaking bad. It is leaking between the top and inside bolt. Everything is tight, I even tried tightening the bolts while trick was running. I'm thinking of covering it with high temp rtv. That's what we did when I built snowmobiles. Any thoughts?

[TopFuel1966]

I'd start by putting a straight edge across all the connector flanges involved to see why they are not fitting together squarely. There is obviously something there like a weld bead or a warped flange or some other evidence of poor quality control on the part of the manufacturer that is leaving a gap between the flanges even with a gasket between them .

[j.rigby15r]

The pipe side isn't welded straight but was able to get it to seal with a paper gasket.

[ImpalaJim]

I've always used manifold gaskets with my headers.

[j.rigby15r]

Originally Posted by ImpalaJim

I've always used manifold gaskets with my headers.

Do you mean the doughnut style gasket?

[Mackie]

Is it a 3 bolt flange style? Then get good quality, new gaskets and if the fit up is poor put a coat of Ultra Copper on both sides of the gasket. Snug the bolts down lightly and evenly and let it set up overnight before full tightening.

I've had good luck doing this with doughnut gaskets, too.

[j.rigby15r]

It is a three bolt tri angle flange. I have good aluminum gaskets in their now.

[Mackie]

If your gaskets aren't too out of shape try the Ultra Copper trick.

[j.rigby15r]

The gaskets are brand new. Only been started once. They are designed to be reusable.

[j.rigby15r]

What irritates me is it sealed with a thin paper gasket coated in copper. But when I put a proper gasket on it leaks. Go figure.

[ImpalaJim]

Originally Posted by j.rigby15r

Do you mean the doughnut style gasket?

sorry Im at the wrong end.

[Mackie]

Originally Posted by j.rigby15r

What irritates me is it sealed with a thin paper gasket coated in copper. But when I put a proper gasket on it leaks. Go figure.

Sounds like the age old problem of header flange misalignment. Think what we went thru back before Ultra Copper. A lot of guys give up and only run OG manifolds to avoid the headaches.

[j.rigby15r]

With misaligned pipes. Is the only fix a cut and weld?

[Mackie]

Originally Posted by j.rigby15r

With misaligned pipes. Is the only fix a cut and weld?

That may be necessary if you can't improve the fit by swiveling the pipe. Assuming that's possible and still meet up with the rest of the downstream exhaust. Or you may stack 2 or 3 of the soft gaskets ...with Ultra C between each for good luck. Not elegant but it just might do.
Another trick, that's used on the manifold to head joint, is start with a moderate tightening and re-tighten after a run up to temp and cool down.

[TopFuel1966]

Originally Posted by j.rigby15r

With misaligned pipes. Is the only fix a cut and weld?

If you're looking for a permanent fix the answer is YES. Anything else is just a band-aid that won't last over the long haul.