I had another thread about exhaust manifold gaskets. I have never found ones that do not leak or blow out.... Thanks OldCarBum!

Quote:
Originally Posted by OldCarBum
I used Remflex header gaskets.
They guarantee to seal leak free.
Go to their web site and review their videos.
They are made in the USA and are actually several layers of material.
They are thick so you’ll need to check your header bolt length to make sure you get enough thread engagement.
Thank You !!
AMAZING!!!!
One of the BEST TIPS EVER!


I have had several combinations of engines and exhaust headers on 2 different c3s over the past 8 years. Some work by me, but most by professional mechanics. The only headers that didn't leak exhaust fumes were the original Ram Horns on the stock '72 engine.

Until Now.

I drove the car for several hours yesterday. It was the first time my wife said I didn't smell like exhaust.

 

Never had an Earls Pressure Master gasket leak. Not sure if they make stock manifold gaskets. I use these on my headers.

 

These look almost the same as the Remflex. How thick is it?

 

Probably the same as you posted but the sealing area is thicker than the retainer so it gets a good positive seal and they are replaceable if need be using the same retainer.

 

One of the issues I have had are with the embossed/raised edge of the copper and aluminum gaskets. The exhaust ports on the headers are D shaped and the header inlet is oval. I could not find oval metal gaskets, only square and round. It looks like Earls have a much wider surface area, but the Remflex are pretty flat. They compressed a lot - from 1/8" thick to 3/32" (a guess - I didn't measure). I think the compression allows them to seal initially, as well as handle heat/cool cycles.

 

The Soft Aluminum and Soft Copper header gaskets are awesome as well. I have used them for over 30 years without a single leak. I thought headers gaskets were supposed to leak a little but with a thick header flange and soft copper gaskets they never leak or get loosened up.

 

I also safety wire my header bolts. My aircraft mechanic shows through on stuff like that. They will never back out unless I cut the wire. BTW my heads are D-ports and my headers are too. Can't remember if the gaskets are D-port shape or not. They haven't been off since I had my headers ceramic coated years ago. In this picture you can kind of see how thick the Earls gasket retainer is.

 

If you're fighting leaks this is THE fix. Used these on countess customer cars when they are complaining. Never had a call back for leaks again, ever. Im a fan. Sorry i didnt see your post earler....

 

Why do so many headers leak so badly that we have to use expensive specialty-made gaskets? I was familiar with all the old horror stories about headers and header bolts. What gives here? Are they using thin flanges or something else marginal? Is the loosening all caused by thermal cycling of the hardware?

Hedman headers come with a thick flange (3/8") that doesn't have issues with hardware getting loose. I put them on the Corvette and that was the end of it. I have never had to do anything to stop any leaks or loosened hardware.

Hello again theandies!
I like the looks of that engine compartment and I did notice the safety wire. I road-raced motorcycles in my youth and still have the jigs for drilling the hardware for safety wire. In the Air Force you must have had plenty of fun as a mechanic. I still have a couple rolls of the safety wire that I use in places where it is important. I used to have a Cessna 172 that I kept in Maryland at VKX airport near Fort Washington, MD and my mechanic was a ex-Navy airplane mechanic. She was good at safety wire and taught me a few new tricks on how the military likes it done. I was allowed to do much of the work on the aircraft myself after my mechanic checked me out. She wanted me to help her ferry aircraft to her shop so I got to fly her early 1960 Cessna back and forth.

My flying instructor was a guy who was able to help win the McKay Trophy down at the Air and Space Museum. He was a B52 pilot back in the day and they saved a very damaged B52 back and were able to get it back to base. They lost all four engines on the starboard wing and were in real trouble. He was a tough instructor but he taught me to fly safely and to enjoy it. The best part is he charged me $4 an hour for lessons in my Cessna 172 which was a deal...

 

Why do some headers leak, that we need special / expensive gaskets?

Steel flexes / warps. (trouble)
Cast iron does not.

A steel header is actually five separate pieces welded together. 4 tubes & 1 flange. (more trouble)
Cast iron is one piece.

The only negative about Remflex gaskets is the bolt holes on the ends.
Other gaskets have a "hook" instead of a bolt hole.
The hook makes things so much easier. Just start two header end bolts into the cyl head. Drop-in the gasket.
Remflex never gave that concept any thought.