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Headers leaking

T

turbocar1

Member
Hi,

My headers are leaking. They have been cut for taller head bolts and welded around the flanges that goes against the heads.

I have tried no gasket, several different types of gaskets, and silicone. Nothing has worked, they always still leak.

I am open to ideas.

Does anyone know where I can find another set of headers, or should I try to have these repaired.

Thanks,
Al
 
Put a straight edge on it, most likely warped when welded on, if you have to buy another set then go ahead and save about $750 and be ready to jump when you see some for sale cause it don't happen often. There was talk of making some from a vendor but nothing solid.
 
Here's an option if you have machine shop skills, or friends with machine shop skills.
Cut the old flanges off
headerflange6.jpg

clean up the tube ends.
headerflange5.jpg

have new ones made
newflangeA.jpg

newflange.jpg


get 'em flat on a surface grinder
headerflange3.jpg


fit them back on each header
headerflange1.jpg

DSnewflangeA.jpg


and have them welded on the tubes on the inside towards the exhaust port. Here's the old vs. new and you can see what happens when the originals have been flattened improperly and that happens easily. but they get thin and are not even anymore which causes problems like leaking where it's thin and crossover pipe mis alignment.
oldandnew.jpg
 
Hi,

I have looked for different headers, so far I haven't found anything. Please let me know if anyone sees anything else.

They just them cut with a straight edge at the last garage I took the car to. They are very thin now. I really can't see how they could work with how thin they are.

I looked at the pictures and I am convinced that I will need to have the flanges replaced. Does anyone know where I can get that done and what it will cost?

Thanks,
Al
 
turbocar1 said:
Hi,

I have looked for different headers, so far I haven't found anything. Please let me know if anyone sees anything else.

They just them cut with a straight edge at the last garage I took the car to. They are very thin now. I really can't see how they could work with how thin they are.

I looked at the pictures and I am convinced that I will need to have the flanges replaced. Does anyone know where I can get that done and what it will cost?

Thanks,
Al
Click to expand...

WS6 just answered your question...
 
My TTA headers were the second set of turbo Buick headers that I re-flanged.

The first set were Jason's dad's GN headers that flanges are readily available from TB vendors, of course that means diddly squat for the TTA head owners.

And I certainly glossed over ALOT of detail in the repair, it was more of a "it can and has been done".
I happen to have a very good machine shop friend who likes to fabricate stuff for me and some of us.
He carefully removed one of the original flanges and made a copies of it out of low carbon steel.
He even made this ball ended spoon maul that we used to re shape the ball flange on the collector. It was time consuming but I never had an exhaust issue ever again.
 
WS6 said:
My TTA headers were the second set of turbo Buick headers that I re-flanged.

The first set were Jason's dad's GN headers that flanges are readily available from TB vendors, of course that means diddly squat for the TTA head owners.

And I certainly glossed over ALOT of detail in the repair, it was more of a "it can and has been done".
I happen to have a very good machine shop friend who likes to fabricate stuff for me and some of us.
He carefully removed one of the original flanges and made a copies of it out of low carbon steel.
He even made this ball ended spoon maul that we used to re shape the ball flange on the collector. It was time consuming but I never had an exhaust issue ever again.
Click to expand...

Would you be willing to repair my headers?

Thanks,
Al
 
I'd have to have a TTA engine on a stand to fit them properly using the crossover. Of which I no longer have...so I'm unable.

Take Robert's advice and call Nick
 
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