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Old 11-29-2008, 12:29 AM   #1
williaty
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Default How Do You Fix an Exhaust Leak

No, really

OK, so the two new pieces of my exhaust are supposed to meet at a flat mating surface (like the stock midpipe to axleback joint). However, because it's cheap Chinese crap, the flanges aren't flat. They're flat on the short axis, but on the long axis, they're higher in the middle than at the edges. So when you actually try to bolt up the pieces, they meet in the middle but have gaps at both bolt holes. I used a thick waffle-board style gasket to try to account for the mismatch. However, it's not enough and the exhaust is leaking.

So what do you do when a gasket is not enough to seal up a bad joint?
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Old 11-29-2008, 06:47 AM   #2
mikeythejew
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Just take it to buckeye brake and muffler on karl RD. They are good at these kinds of things.
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Old 11-29-2008, 12:59 PM   #3
williaty
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I do all the work on my car. I won't pay someone to do something I can do myself.
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Old 11-29-2008, 01:22 PM   #4
UkNuck
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fwiw I had the same issue at a turbo-to-downpipe flange - I put it back together with a stock gasket + bead of Permatex Copper (following the instructions carefully i.e. finger tight / cure overnight / torque down) and it has been fine for 3-4 years - even though it's only rated to 700F intermittent - I'd think it's worth a shot since your temps should be lower at the midpipe
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Old 11-29-2008, 01:25 PM   #5
williaty
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That's the high-temp coppper RTV gasket material you're talking about, right? Kind of looks like orange silicone caulking?

Someone left a tube of that here. The instructions are all gunked over though. Do you torque the bolts down before or after you let the stuff cure overnight?
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Old 11-29-2008, 01:39 PM   #6
UkNuck
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http://www.permatex.com/documents/td...tive/81878.pdf

looks like I was wrong about initial 'finger tight' - it says to torque to spec right away

although on the back of the tube I have it says "Do not squeeze out silicone by overtightening bolts. Dries in 1hr, fully cures in 24hrs."
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Old 11-29-2008, 04:14 PM   #7
WeldingHank
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use the copper RTV and let it set about 30-40 mins after you torque it. I was using that for a while to seal my donut flange cat-back to my flat-flange DP. it works wonders till i found a donut gasket to stick in there and not restrict my exhaust.
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Old 11-29-2008, 05:40 PM   #8
Uncle Scotty
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clean all the surfaces with some acetone...let dry....use that gasket goop....do it before you need to drive the car for at least 18 hours if possible...longer is good

it should cure your leak

the only way to make that fit better is to take it off and cold work it back flat....if you dont know how to do this, you may make it worse
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