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Old 08-15-2010, 07:58 PM   #1
konmann
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Default Help me make an exhaust gasket!!

I have just found a small exhaust leak at the mating flange area of a 2 piece catted down pipe (Mad Dad V2). The OEM gasket has a unique profile and is of a metal/fiber material that I think is too thin for its intended purpose, as there is a soot trail at the joint.

I would like to replicate the shape of this gasket using dead soft copper. Anyone know where I can get sheet stock of this material and the best way to make this?

I figured on using tin snips and a holesaw to get the profile I need or even waterjet cutting if it isn't too expensive.

For anyone who has done someting like this, should I form a channel or two around the perimiter of the gasket to ensure better sealing?

Regards,

Kon
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Old 08-16-2010, 08:39 AM   #2
boost junkie
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You can get sheets of gasket material and cut your own. I have done this before, I believe the material was made by Mr. Gasket (you can get it at summit, jegs, etc.). I sprayed both sides with copper gasket seal just to be safe and it never leaked.
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Old 08-16-2010, 01:57 PM   #3
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if its just a small leak i just coat both sides of the gasket with copper rtv. ive sealed turbine housings to manifolds and downpipes and all kinds of stuff sometimes without even using a gasket just using the rtv. just let it dry before you run the car if its something under pressure.
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Old 08-23-2010, 12:29 PM   #4
leecea
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I bought a sheet of exhaust gsket material from Amazon, then cut two gaskets and sandwiched them together with a little copper RTV. That was for a used axleback where the flange wasn't perfect. It seems to be holding up.
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Old 08-25-2010, 12:08 AM   #5
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I have used tin foil (many layers) before and it worked good so I don't see why your plan wont work. I figured as long as it was even and can hold up heat it will work and it did for a while.
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Old 08-25-2010, 11:14 PM   #6
ULL_WRX
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I use a sheet of gasket material and place it over the part I am making a gasket for and tap it with a hammer and it will cut the gasket to match up perfect.
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Old 09-13-2010, 03:59 PM   #7
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are you opposed to just buying an aftermarket high quality gasket?

Will
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Old 09-19-2010, 01:44 PM   #8
arisking
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Of course Grimmspeed would say this...LOL. But yeah, when I take apart my header, uppipe, turbo and all that to wrap I'll actually be buying a GS gasket set. Makes more sense and doesn't actually cost too much anyway.
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Old 09-24-2010, 12:29 AM   #9
konmann
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Wil you dont make the gasket I need. It is more oval shaped, like the factory rear cat to exhaust pipe gasket from an 04-05 STI.

I have since gathered the tools and material to make my own gaskets-
Felpro exhaust gasket material
Wiss snips (assorted)
Greenlee punches
Permatex copper gasket spray

The 3 layered gasket seems to be holding up too although I will soon move to a dead soft aluminum gasket for both the inlet and outlet of the second cat pipe, since it has more resilience thant the soft exhaust material I have been using.
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Old 09-26-2010, 10:18 PM   #10
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ever think about having the 2 surfaces decked then boling them up using nothing? Ive seen it done many times in aluminium heads with ss headers on v8s., we tried several gaskets and couldnt get a seal. After they were decked it was perfect with no gasket, been 6 years now with no problems.
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Old 09-28-2010, 06:49 PM   #11
konmann
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Rex,

I will entertain that option when I have enough time to have both pieces of the down pipe off. I knew I should've had the flanges surfaced after I had them finish welded in the first place.

Any insight into the ideal surface roughness for these flanges if they are to seal with no gasket? I imagine that would be pretty important for some type of "bite" between the mating flanges.

Regards,


Kon
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Old 09-28-2010, 08:03 PM   #12
scby rex
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No roughness, decked smooth.
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Old 09-30-2010, 10:42 PM   #13
konmann
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Rex,


Just to clarify, I mean surface roughness like what is associated with copper head gaskets and a freshly decked block half or milled head. These surfaces may feel smooth to the touch like what you mean, but actuallly have a roughness to them even though it is invisible to the naked eye. If the roughness is not within a certain range, you run a higher chance of blowing the head gasket.

By the way, do you have pictures? I definitely would like to see the flanges. After welding the flange to the exhaust pipe on the outside, did you finish weld the inside lip of where the flange and exhaust pipe meet? That's what I ended up doing to ensure no changing of the relationship of the flange to the exhaust pipe when things get hot.


The gaskets I made are still holding up and I saw no carbon traces at the flange ends of the mid pipe.





I did however see where the metal hanger which holds the midpipe to the transmission mounted exhaust bracket has been cracking. This bracket is roughly 18 gage in thickness and welded in such a way as to prevent the appropriate direction of movement due to thermal expansion.



The end of the bracket at one of the weld locations is completely severed and the bracket at the second location is severed roughly 1/4 of the way through. Its only gonna get worse:




Either way the bracket needs to be replaced so I will either canibalize the hanger from the stock exhaust and weld it on in this area or I will fabricate one that has the same shape and dimensions.

If anyone was curious the downpipe I have is the MadDad V2 2 piece catted.

Last edited by konmann; 10-01-2010 at 09:27 AM. Reason: pics added
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Old 11-14-2010, 10:57 PM   #14
konmann
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Default OEM bracket salvaged and prepped to replace MadDad bracket

Well the bracket shown in the last post finally broke free. It was only a matter of time. To replace this craptastic bracket, Ive salvaged the midpipe bracket from my OEM exhaust and opened up the ends to fit a 3" pipe.






Compare the way MadDad had the bracket welded with the way subaru did it. Note the OEM bracket was welded in an entirely different plane as well as being made of a much thicker material. Once it is welded on, I am convinced I won't need to worry about this bracket again.

If you'd like to do this as well, a cutoff wheel will work along with a chisel to break the bracket free off the pipe after the cuts have been made.

Once that is finished use a disc grinder and a grinding wheel to dress the edges and remove excess metal where needed.

Use a vise and hammer to flatten out the ends of the bracket so they fit the larger exhaust pipe.

Regards,


Konmann
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Old 11-14-2010, 11:46 PM   #15
Uncle Scotty
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I have made gaskets outa copper sheet.....works well

I also have used the permatex copper spray gasket stuff with great results---follow the drections ...on them


being able to make a gasket outs some already at hand material that is in the garage/shed is much better than getting stuck on a project and having to wait for a gasket to show up

hell...I made a bpv gasket outa a silver bullet 12pk box end and copper gasket spray.....it never leaked
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Old 11-15-2010, 07:56 AM   #16
konmann
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Heck yeah Scotty!
Always better when you can DIY!!

Regards,


Konmann
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Old 11-15-2010, 10:41 AM   #17
WeldingHank
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Quote:
Originally Posted by Uncle Scotty View Post

hell...I made a bpv gasket outa a silver bullet 12pk box end and copper gasket spray.....it never leaked

LOL, and I thought I was the only one who did this. I use soda box for that gasket all the time with RTV smeared on both sides.
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Old 11-15-2010, 12:43 PM   #18
mowgli29
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Quote:
Originally Posted by Uncle Scotty View Post
I have made gaskets outa copper sheet.....works well

I also have used the permatex copper spray gasket stuff with great results---follow the drections ...on them


being able to make a gasket outs some already at hand material that is in the garage/shed is much better than getting stuck on a project and having to wait for a gasket to show up

hell...I made a bpv gasket outa a silver bullet 12pk box end and copper gasket spray.....it never leaked
I agree completely about not having to wait for gaskets. Hooray for improvisational skills.

When I scored an ebay TMIC for 50 bucks, I spent hours filing the bpv flange flat...then realized my gasket was toast too. Out of desperation, I made a "temporary" one out of cardboard. That was a good 10 months ago.
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Old 05-25-2012, 02:12 AM   #19
bue car
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anyone buy copper and what kind? I need it for a downpipe gasket.
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Old 05-26-2012, 07:12 AM   #20
Uncle Scotty
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Quote:
Originally Posted by bue car View Post
anyone buy copper and what kind? I need it for a downpipe gasket.

I think the sheet I got came from a hobby/crafts shop...but not for a dp gasket.


hell....roll the dice, man....try it and see what's up
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Old 05-26-2012, 02:01 PM   #21
bue car
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as we spoke in the other thread, i will.. just thought i bump this for those who were subscribed... im also thinking of v banding it, will be fun, ss / cast iron
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