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Old 02-05-2002, 09:03 PM   #1
jimb
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Lightbulb DIY Uppipe Gaskets

Ok. The only way to get my uppipe to stop leaking is going to be a totally custom gasket at the lower flange. Anyone got any leads on gasketing material? I'm going to get some Alumina or Alumina-Silca sheeting. I'm a little concerned about the 'compressability' of the material. Anyone else ever use anything with any success?

Thanks,
jb
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Old 02-06-2002, 12:17 AM   #2
jimb
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bump

cmon, 33 reads.. Somebody has got to know something about gasketing material

jb
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Old 02-06-2002, 01:55 AM   #3
alltractionWRX
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No one sells the gaskets for the up-pipes?
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Old 02-06-2002, 06:46 AM   #4
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Try your subaru dealer?
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Old 02-06-2002, 07:14 AM   #5
jimb
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Nonono! I'm looking for the material to make gaskets, not the oem gasket. I've tried it, and they don't work. A bunch of folks have had to stack the lower gaskets, including myself. I'm trying to make a thicker gasket that will take care of any lower flange leaks.

Anyhow, I've got a couple of leads on some 'space age' gasketing in varying thicknesses that'll hopefully do the trick.

jb
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Old 02-06-2002, 07:18 AM   #6
Happy
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Why is it leaking ?

Since the up pipe will be a straight swap, the stock gasket should be fine. Although always use a new one.

If a new gasket won't seal, either the flange surfaces aren't "true", or they aren't bolting together flat because one of the flanges hasn't been welded on right.

Try loosening the bolts on the uppipe, AND on the turbo, then tighten up the uppipe bolts first, then the turbo.

Happy.
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Old 02-06-2002, 07:36 AM   #7
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Yea see, that's the easy part, but it's a long story. I've probably reinstalled the damn thing about 3 times already. The lower flange just won't seal.

jb

Last edited by jimb; 02-06-2002 at 02:10 PM.
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Old 02-06-2002, 08:52 AM   #8
Austin
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jim - when I was having problems, I tried a bunch of different things. One of the best was a Jeep exhaust gasket (made by Felpro, IIRC). It had the exact ID of the uppipe, was thicker than a cd jewel case, and had a metal crush ring in it - made from metal impregnated high temp black stuff... just can't remember the name right now.

Best bet would be to go to the best small town auto parts store with your stock gasket and have the guy match it up with a thicker one.
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Old 02-06-2002, 08:53 AM   #9
Jon [in CT]
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Have you tried removing the turbo and then installing the up-pipe? The idea is that there should be absolutely no pressure at all against the up-pipe from above (other than its own weight) while you torque the up-pipe to the exhaust manifold collector.
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Old 02-06-2002, 08:57 AM   #10
jimb
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The last time under, I unbolted the downpipe, the lower uppipe flange, and the manifold. Than retorqued everything down starting with the lower flange, then the manifold, and finally the downpipe.

jb
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Old 02-06-2002, 09:08 AM   #11
trboCIVIC&WRX
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I betcha I know where you got the uppipe from....

Mine wouldnt seal either... I am having a friend reweld the lower flange on at the CORRECT angle....

How about trying some copper? That stuff likes to be compressed....

just an idea...
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Old 02-06-2002, 09:39 AM   #12
BigRich
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This may be B.S., but what about using 2 gaskets together? I read that somewhere here on i-club.

I hate the problems I am having with my uppipe. It's going to another shop this weekend to try to fix these leaks. I get a loud sputter sound from that area if the cars is cold or not. It happens when I'm at full throttle and my car hits a bump. Very hard to explain, but it's definitely related to the uppipe install.

-- Rich
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Old 02-06-2002, 09:43 AM   #13
jimb
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I'm currently using two gaskets at the lower flange, it doesn't even come close to working with a single gasket.

trbo, pm me with your guess. I'd like to see if everyone with this particular pipe is having a problem.

jb
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Old 02-06-2002, 08:07 PM   #14
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jb,

Have you tried Aircraft Spruce for gasket materials? I don't have my catalog (in storage with the rest of my garage!) but they have a lot of wierd stuff....

Lee
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Old 02-07-2002, 03:29 PM   #15
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Who makes the up-pipe?
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Old 02-07-2002, 04:00 PM   #16
Leonardo
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I have not replaced my gasket but it's leaking too!

Austin, any chance you can tell us what gasket # it was?

Leo
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Old 02-07-2002, 05:08 PM   #17
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So what is the big secret on what up-pipe you have? This is a community where we inform each other on various bits of information without influence from vendors, dealerships, or SOA.

Speak up. It will insure quality products will be made in the the future.
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Old 02-07-2002, 05:41 PM   #18
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Leo - Sorry, no can do... I checked my records, but I never wrote the part number down. I do remember it was a Jeep exhaust gasket, and it was shaped more like an oval (the oem gasket is shaped more like a diamond), so I had to cut out the holes only the ends for bolts to fit through, but the ID was the same.
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Old 02-07-2002, 06:02 PM   #19
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Cut out cereal boxes work good
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Old 02-07-2002, 06:12 PM   #20
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Quote:
Originally posted by BigRich
I get a loud sputter sound from that area if the cars is cold or not. It happens when I'm at full throttle and my car hits a bump. Very hard to explain, but it's definitely related to the uppipe install.

-- Rich
I think I have your explanation. I get that loud sputter every time I step on the gas. There is a crossmember that runs right under the up pipe. The clearances are very small. As most people know, the engine torques over to one side when you accelerate. So, when you're at WOT, the engine will be torqued over as far as the engine mounts will allow. Then you hit a bump. This causes the engine to twist just a little bit more, allowing the up pipe to come into contact with the previously mentioned crossmember. That sputter is the engine assembly(via the up pipe) vibrating against the frame. If you were to go WOT in reverse and hit a bump, you wouldn't get this noise, because the engine is torquing over in the other direction. When I first started getting that noise(right after I installed my second up pipe), I had the hardest time figuring out what it was. It would do it when I went around left turns, but not right, and only in forward gears, and only once I was in boost. I guess there wasn't enough power to torque the engine enough to hit. It actually hits when I start the car too, and thats how I figured it out.

For now, it sounds like I have a V8 with open headers when I am accelerating. My up pipe is so far off spec, I thought maybe my engine mounts had failed already. I had a Subaru tech check them out and he said they were fine. I have a replacement up pipe(third one) with a flex joint welded in sitting in my trunk. I'm waiting for my down pipe to come in before I install it.

I think the only solution to this is to replace the up pipe. Whoever sold it to you should send you a new one. My up pipe vendor has sent me two new ones since the first one fit so poorly that it would never seal on the lower flange. The latest one sent to me was custom built for me. I asked him to make a pipe with a flex in it, and it was here within a week. Great customer service from Ultimate Racing.
ok, sorry for hijacking your thread.
Tim
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Old 02-07-2002, 07:06 PM   #21
Akiata
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Ok, what uppipe is everyone using!!!

I know Austin has a Vishnu uppipe. I am having a shop install my Vishnu uppipe next friday so I need to tell them so they can get the correct parts if needed.
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Old 02-07-2002, 07:29 PM   #22
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It's hard to believe, given all the leaks reported in conjunction with removing/installing the up-pipe from underneath the car, that nobody so far is willing to try the Subaru method of replacing the up-pipe. In essence: remove both rear cats as a single unit; remove turbocharger; remove up-pipe from the top. Installation is reverse of removal, using all new gaskets. This method assures that as you move downstream from the manifold, each piece is attached without any pressure (other than its own weight) acting on it to prevent it from seating flush and secure at its upstream connection.
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Old 02-07-2002, 09:28 PM   #23
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I've got an alamo motorsports uppipe. Small leak in mine too.
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Old 02-07-2002, 10:06 PM   #24
V10Guy
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I was successful with a Felpro 60025 gasket. The outer dimension was similar to stock, but the hole was a little larger than the uppipe opening. The bolts fit perfectly and I was able to slide it in without undoing everything from above. It has a crush ring and the typical cork-like material all around. Perhaps having the ring away from the opening is more efficient in sealing since it is closer to the 2 bolts. I have the latest Vishnu pipe and you can see the manifold flange bend to meet it. I bet like others that too much torquing is causing a separation in the middle.
I had the autoparts guy take the stock uppipe and test fit everything he had in inventory.
Hope that helps. (Only cost $4.00 so worth a try)
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Old 02-07-2002, 10:49 PM   #25
DJWRX
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I am going to have to agree with V10guy. I think the reason for so many leaks is that two bolt flange. If you overtorque it just a little bit, you get separation in the middle. That is a high pressure zone right before the turbine and it needs more strength in the flange to hold it all in.
My first concern upon recieving my first up pipe was that lower flange. All I can say is DON'T OVERTIGHTEN!!!

Tim
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