exhaust leak

[JRas]

I installed a hotshot header awhile back bolted it up to the dummy cat on my S14... noticed it was leaking about a week ago and finally got around to messing with it.

I found the leak.. it was in between the header flange and the cat flange..

basically the flange on the header is smaller than the cat flange so part of flange and gasket hang below the header flange.

this leaves about half the gasket sealed, and the other half hanging.. so it ends up burning up

header is 2.5in and cat is 2.5 in

the flange on the header is 3 1/4in and the cat is 3 3/4in

http://img13.imageshack.us/img13/2759/exhaustleak002vw1.jpg
http://img201.imageshack.us/img201/1763/exhaustleak006ab0.jpg

ideas on how to fix this?

the flanges meet perfectly going from the cat to the exhaust and no leak is present. but also the gasket is also higher quality.

the gasket I'm currently using between the header and cat is some $3 one from the local auto store.. felpro or someshit.

[murda-c]

exhaust shops should be able to reflange it for you.

[MisawaJason]

RTV that shit

[!Zar!]

Is the gap even all the way around?

You might be able to wiggle the cat up just a tad bit more to even the gap up around the whole thing.

But the auto part store gaskets won't last that long even if it were to fit.

[ZX88]

RTV that shit

yes. this will work.

[JRas]

Is the gap even all the way around?

You might be able to wiggle the cat up just a tad bit more to even the gap up around the whole thing.

But the auto part store gaskets won't last that long even if it were to fit.

I replaced it with a new gasket, but it still leaks a little bit.. I think I'm going to order a better gasket and just replace it with that.

anyone know if a test pipe will have the same flange size as the header?

[Matej]

Go to the parts store and buy a stock gasket.

[murda-c]

I replaced it with a new gasket, but it still leaks a little bit.. I think I'm going to order a better gasket and just replace it with that.

anyone know if a test pipe will have the same flange size as the header?

my test pipe i got off ebay was the same size-maybe a little bigger-than the stock cat.

[projectRDM]

The OE stamped stainless gaskets work good in that situation, you'll need to trim the bolt holes out to fit though. Or, a Greddy/HKS metallic gasket will definitely seal it if you don't mind paying $20 to get one shipped.