OK, I bought an RRM header used. Just looking at it, the black deposits showed an exhaust leak. It was at the rear of the header/downpipe connection.

I thought nothing of it and installed. After firing it up, the RRM header and Buschur downpipe had a huge leak. Same spot. So I removed the downpipe and put the stock one back on (because I'm selling the Buschur DP, in case you were wondering). Still leaks. I haven't removed anything, but the header/downpipe connection is the problem again.

Could it be the header? Or am I just hooking something up wrong everytime?

 

Check your gasket. maybe it's time to replace the one you have in there now?

 

Been through a few, actually.

Might try a higher-quality next time, though.

 

take the header off and take it to a machine shop. The flange is most likely warped and slowly eats through gaskets like you said you replaced already. If the flange is warped nothing will stop a leak. Had mine resurfaced and all is good. I also invested in some copper gaskets so no more blow outs for insurance. Look for the 2 1/2" inner diameter ones that SCE makes. You need to ream out the two mount holes a little to make it fit but other than that-no problems!

 

Thanks - I might try that with the header and the gasket.

 

Did you use any copper sealant?

 

Went back to stock header/DP for the partout (see my sig). But I have another exhaust leak, of course. I think I'm just cursed.

 

If your leak is at the seals than you need to get a new sealing plate(I can't remember what they are called) to go between the upper and lower parts of your headers and a tube of copper foil sealant. Put the sealant on all three parts of the header as you bolt it back on. make sure you get any gunk off that might be there before you add the copper seal.