Blowing Gaskets - Aftermarket Header :( - Lexus IS Forum
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post #1 of 25 (permalink) Old 04-10-2019, 06:05 AM Thread Starter
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Blowing Gaskets - Aftermarket Header :(

Hey guys,

I know this topic has been discussed before, but I thought I would bring it up again to see if people had ideas about how to solve this. First off, I know one way to solve it would be to drop $1k-1.5k on either dezod or figs header....maybe one day.

I have a DNA header and when paired with either the stock midpipe or a megan racing midpipe I keep blowing gaskets. I know that for my stock midpipe I can look at it and tell the surface isn't true anymore....too much rust, etc. But I expected the megan racing midpipe to fair better. This morning I drove to work to test my own homemade gasket from Mr. Gasket material....it didn't even seal from the get go showing how poor the two surfaces mate.

One thought I've had is take it to an exhaust shop and have them chop off both ends and either permanently weld the two together (would make it more difficult to remove but not impossible) or vband the two collectors.

Two questions:

1. Is there anywhere we can buy just that aftermarket shaped gasket? I see a DNA kit on ebay for $19 but it includes the manifold gaskets and bolts too.....All I need is the double flange gasket.

2. Is there another good solution for this I'm not thinking of?

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post #2 of 25 (permalink) Old 04-10-2019, 08:48 AM
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youre debating on whether to spend 20 bucks vs $1-1.5k.... I'd bite the bullet and find some change to buy the 20 bucks of gasket and useless other materials. just my 2cents

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post #3 of 25 (permalink) Old 04-10-2019, 08:59 AM
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A pair of V bands is going to be tough to fit. The two tubes are awful close together.

I could never expect any of my local exhaust shops to do any kind of satisfactory custom work on a project like yours. Maybe your local shops are better. Another concern would be whether or not they'll work on an "off road" exhaust at all. In my area, this would need to be done by a specialty shop that focuses on custom racecar fabrication stuff. I'd expect to pay a couple hundred bucks for them to execute a nice solution.

I've fixed similar issues with a hand-operated belt sander, a metal straightedge and patience. I simply sanded the flanges until they were nice and flat, taking it easy the way and checking my work often so that I didn't grind an unwanted angle into the flange.
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post #4 of 25 (permalink) Old 04-10-2019, 10:25 AM
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I struggled with replacing the gaskets in that shit header design for years and finally put my stock headers back on, simply not worth the hassle. I've used liquid copper, made my own, bought aftermarket, and combinations of all together.
There will be a Megan header in my trash next week if anyone wants it

You have a few options:
1: lots of money for well designed headers
2: stock header back in
3: weld the two together and hope you never have to remove them
4: I saw a thread years ago but could never find it - but someone mimicked the stock header flange design with their aftermarket headers. He had two pipes welded into the outlets of the header so they would slip into the y-pipe. You'd most likely need to contact an exhaust shop because the tubing diameter won't be standard since it's going inside. He might have even cut a pipe length wise to help it compress... ugh I wish I could find that thread.

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post #5 of 25 (permalink) Old 04-10-2019, 12:03 PM Thread Starter
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Originally Posted by black86 View Post
youre debating on whether to spend 20 bucks vs $1-1.5k.... I'd bite the bullet and find some change to buy the 20 bucks of gasket and useless other materials. just my 2cents

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Yeah, it's not so much spending $20 but rather spending $20 on a design I know will fail at the next track day. But you may be right it might be the only option.
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post #6 of 25 (permalink) Old 04-10-2019, 02:06 PM
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If you're tracking the car anyway, the real headers sounds like a no brainer to me. Hearing these issues makes me glad I just "saved" my money and spent it on the right parts to begin with. No regrets buying the $1k headers twice.

First the $20 rotors installed backwards , and now this
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post #7 of 25 (permalink) Old 04-10-2019, 03:52 PM
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Quote:
Originally Posted by humbucker87 View Post
Hey guys,

I know this topic has been discussed before, but I thought I would bring it up again to see if people had ideas about how to solve this. First off, I know one way to solve it would be to drop $1k-1.5k on either dezod or figs header....maybe one day.

I have a DNA header and when paired with either the stock midpipe or a megan racing midpipe I keep blowing gaskets. I know that for my stock midpipe I can look at it and tell the surface isn't true anymore....too much rust, etc. But I expected the megan racing midpipe to fair better. This morning I drove to work to test my own homemade gasket from Mr. Gasket material....it didn't even seal from the get go showing how poor the two surfaces mate.

One thought I've had is take it to an exhaust shop and have them chop off both ends and either permanently weld the two together (would make it more difficult to remove but not impossible) or vband the two collectors.

Two questions:

1. Is there anywhere we can buy just that aftermarket shaped gasket? I see a DNA kit on ebay for $19 but it includes the manifold gaskets and bolts too.....All I need is the double flange gasket.

2. Is there another good solution for this I'm not thinking of?

I use compressed graphite from Remflex. Remflex Exhaust Header / Manifold Gaskets It is easy to cut and have not had any issues. Even on slightly uneven surfaces.
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post #8 of 25 (permalink) Old 04-10-2019, 05:32 PM
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Originally Posted by TobiasSing View Post
If you're tracking the car anyway, the real headers sounds like a no brainer to me. Hearing these issues makes me glad I just "saved" my money and spent it on the right parts to begin with. No regrets buying the $1k headers twice.



First the $20 rotors installed backwards , and now this
which header? my parents threw out my mazzuri v2

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post #9 of 25 (permalink) Old 04-10-2019, 08:25 PM Thread Starter
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Originally Posted by TobiasSing View Post
If you're tracking the car anyway, the real headers sounds like a no brainer to me. Hearing these issues makes me glad I just "saved" my money and spent it on the right parts to begin with. No regrets buying the $1k headers twice.

First the $20 rotors installed backwards , and now this
Dude the struggle is real. I am both a car nut and a personal finance FIRE (financially independent retire early) prescriber. The two things couldn't be further from each other. The most depressing thing is the spreadsheet of spending on this car so far....could be worse for sure, but there have been some mistakes This last set of RE71r's lasted two weekends and are now done.

My monthly car budget to savings ratio is about 1:10 so maybe it's time to spend a bit more for once. I'm going to see if one of these DIY gaskets can hold with the megan midpipe.
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post #10 of 25 (permalink) Old 04-10-2019, 08:31 PM
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Originally Posted by humbucker87 View Post
Dude the struggle is real. I am both a car nut and a personal finance FIRE (financially independent retire early) prescriber. The two things couldn't be further from each other. The most depressing thing is the spreadsheet of spending on this car so far....could be worse for sure, but there have been some mistakes This last set of RE71r's lasted two weekends and are now done.



My monthly car budget to savings ratio is about 1:10 so maybe it's time to spend a bit more for once. I'm going to see if one of these DIY gaskets can hold with the megan midpipe.
by weekends is that both days with 8 sessions each for 20 mins?

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post #11 of 25 (permalink) Old 04-10-2019, 08:41 PM Thread Starter
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A lot of mine are 4, 25 minute sessions each day. So I'd guess I got 7 or 8 hours out of them. They are fast though for 200TW.
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post #12 of 25 (permalink) Old 04-10-2019, 08:59 PM
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do they always blow in the same spot? With both the mid pipes?

If so then you can pretty much say that is the weak area on the headers not the mid pipe. Can it be machined flat again? Or can the shop cut it off and weld on a new flange of better quality and flatness?

If the flanges are flat there is no reason it wont seal for these the same as it will for a stock header, if both are using the same flange.

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post #13 of 25 (permalink) Old 04-11-2019, 03:53 AM
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I've got OEM gasket on my header. Those you buy at Toyota shaped like a donut. Since th header is a bit bigger than oem manifold I've bought some Toyota Tundra exhaust gaskets. I can tell you the part number later. Still got the bag at work

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post #14 of 25 (permalink) Old 04-11-2019, 05:49 AM Thread Starter
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Thanks guys for the suggestions. Mathieu that would be interesting to take a look at the tundra gaskets.

@Pnut00 I think it has been blowing out in the same spot so I should take a closer look at the flange and make sure there isn't something weird there. To be honest the more I look at my stock midpipe there is no way it will ever seal against a flat flange like the aftermarket one. Because of the age and rust it's not even close to flat.

Another interesting observation I made last night (although not surprising given the price of the DNA header) is that the exhaust gasket that blew out did not align with the exit of the header very well at all. Below I drew a red circle approximately where the header pipe would line up with the bolts are through the holes. Meaning that the bottom of the gasket would be getting non stop hot exhaust gas passing over it. As suggested earlier I'm going to try and cut my own gasket from remflex material and make sure it lines up much better.

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post #15 of 25 (permalink) Old 04-11-2019, 02:38 PM
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Quote:
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which header?
on my second Dezod greens now

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Originally Posted by humbucker87 View Post
Dude the struggle is real. I am both a car nut and a personal finance FIRE (financially independent retire early) prescriber. The two things couldn't be further from each other. The most depressing thing is the spreadsheet of spending on this car so far....could be worse for sure, but there have been some mistakes This last set of RE71r's lasted two weekends and are now done.

My monthly car budget to savings ratio is about 1:10 so maybe it's time to spend a bit more for once. I'm going to see if one of these DIY gaskets can hold with the megan midpipe.
I hear ya. If you saw my spreadsheet, you'd probably have an aneurysm lol. But I've definitely learned that it's just worth it, literally, to do it right the first time. Spend the big bucks now, or later with the extra you wasted on cheap stuff. Besides, what good is money if you never spend it? lol.
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