Do you have that dreaded unfixable header->downpipe leak? I found a solution!

[JohnD1079]

many of us have had to replace our header for one reason or another, with a large majority of us using some kind of crappy ebay header from some country with horrible quality control. many times these headers dont have a gasket intent (like mine) come with a crappy gasket that blows or non at all (like mine), and its practically impossible find a gasket that holds up the the heat, while just about any silicone handmade gasket will blow(literally too ). well Ive come up with a solution.

you know those thick aluminum food containers used for catering? get the lid, and fold it up a couple times. not too much, about 8 layers of foil is what i used. put high temp silicone between the layers and let it dry for a bit, and make sure its flat. now put the aluminum on top of the downpipe, and hammer in holes where they belong. if youd like you can cut the foil in the hole and bend it back, adding an extra layer right around the circles, but if you do this id recommend buying metal oring and place them there, right under the layer to ensure a perfect seal. put the foil between the header and downpipe and slowly tighten each bolt in rotation untill you feel that the orings crush. if you dont use the orings, use an air gun at the end to vibrate the foil into place creating a seal.

i didnt use the orings, and so far after 1500miles + it still holds up, and that includes two 500 mile roadtrips.

[gloryaccordy]

This sounds like a fire waiting to happen TBH

[cp[mike]]

basically you created your own multilayer aluminum gasket, like they come with... but instaed of that crusty ceramic in the center that blows out, this is layer and layer of squishy sticky silicone between aluminum

this sounds like brilliance and something i will be doing next time i take apart THIS GOD DAMN HEADER THAT WONT STOP BLOWING AFTER 1 DRIVE

[C-Rod]

You have any pics of your final product?

[JohnD1079]

basically what cp mike said except I didnt use that much silicone. Kinda just put it there for peice of mind.

Now sure if this picture will help much but:

[dj_ender]

All I did to fix my leaking exhaust was to get under the car and tighten the damn bolts and voila! No leaking exhaust. But mine wasn't the usual "eBay" header, although it was a Megan Racing header from MR directly, but I still hear people complain about MR. I have nothing bad to say about mine and I've had it for almost 2 years.

[Tippey764]

Why not just use the subaru gasket?

No offense but that looks like a nasty hack repair job

[Accrdwgnguy]

x2 on Subaru gasket, works quite all right, and cheap.

Other thing is you need to loctite the studs to the upper header, as they keep backing out.

[foamypirate]

This sounds like a fire waiting to happen TBH

Yep, the aluminum is just going to burst into flames some day.

ROFL.

[JohnD1079]

this is the first time ive heard of "the subaru gasket"

Tell me moar plz.

[Accrdwgnguy]

go to Autozone or Advanced or any parts store really. Ask for exhaust manifold gasket for a 1995 Legacy or any late model Subaru really.

You will get this



And yes they do come as a pair, so you will have an extra.

You may need to enlarge 2 of the mounting holes for it to fit.

I paid $12 for a Felpro 2 pack at Advanced Auto

[cp[mike]]

the subaru one looks just like every other gasket that blows out. ive found other oem "similar" gaskets and trimmed holes to fit, and they blow out also. and my bolts are cranked down.

[Accrdwgnguy]

The Felpro Subaru gaskets have a metal ring around the inside of the hole.

[djcaz_aom]

Just use a vise and a metal hole saw on the downpipe flange and use OE round washers for an ex downpipe.

[JohnD1079]

The Felpro Subaru gaskets have a metal ring around the inside of the hole.

then it should hold. The only thing that will work as a gasket there is metal. Im pretty convinced anything else will be blown out.