1500 header install. Gasket tack?


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Quick Cal
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1500 header install. Gasket tack?

Post by Quick Cal »



I'm replacing a rotted exhaust chamber on my 96 1500. I took both headers off. I have new crush washers to install in the head. I seen a video where a guy said to use "gasket tack" to hold them in place so they don't fall out before you get the header installed.

What he used reminded me of the old 3m yellow snot. I can't find anything that looks like that. What are you guys using to hold the crush washer in place? Thanks


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Rambozo
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Re: 1500 header install. Gasket tack?

Post by Rambozo »

I've always just squished them a little with my hand so they are not quite round. Then friction will hold them in place. Not a fan of any chemical that will ultimately burn off on exhaust. Also be sure there are no old ones stuck in the head before you put the new ones in.
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Re: 1500 header install. Gasket tack?

Post by Greenwinger »

Due to ongoing leaking issues with my header to collector box I had to change them 4 times in one month trying to fix the small exhaust leak. I've got it down to changing the header gaskets to about 15 min. Just be careful installing them I have never had much trouble with them. and as Rambozo states make sure to get the old ones out. Don't over tighten the bolts either, If I'm not mistaken the spec. is 7 lb/ft ( I am probably wrong )which I always found a little light. You will feel the washers crush as you tighten them. Remember to go over all the bolts several times until they are all the same snugness. And if possible use the OEM copper gaskets the aftermarket ones don't last long and don't seem to seal very well, well not for me anyways. Good luck
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Quick Cal
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Re: 1500 header install. Gasket tack?

Post by Quick Cal »

Rambozo. Great tip on distorting the gasket.

Greenwinger. Do you think the leak was caused by the dent put in the pipe from the clamp? I'm installing a used exhaust chamber and it does have that ring around the tube.

I don't know if this applies to Goldwings, but seems like a good idea. There's a seam on the copper gasket. If you install it in a certain direction, the guy in this video says they can blow apart. Seems logical to me. So I'm going to pay attention on wich way I install them.





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Also. This chamber came from Cali. So it's not all rusted up. But there was a little rust looking stuff between the gasket and the inner tube. So I cleaned it with a wire wheel. Was it originally coated with something, or painted? Should I paint these tubes with header paint maybe? Or will it just burn right off?




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Re: 1500 header install. Gasket tack?

Post by Rambozo »

I've never seen Honda gaskets that were flat on one side. Always round and both the header and cylinder head have flat bearing surfaces that crush the gasket. With a lot more pressure than they typical two stroke with springs. If properly installed the seam doesn't even see exhaust pressure as it is on the outer surface past the centerline where the sealing takes place.
Header paint or other high heat coating will provide some rust protection. No idea how long it will last. It's far enough from the head pipes that it could hold up and protect from road spray. There are professional ceramic coatings that I know work great, but not really a DIY project as they have to be baked on. No idea if the spray can ceramics are snake oil or if they really work.

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Quick Cal
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Re: 1500 header install. Gasket tack?

Post by Quick Cal »

Rambozo wrote: Mon May 15, 2023 7:33 pm I've never seen Honda gaskets that were flat on one side. Always round and both the header and cylinder head have flat bearing surfaces that crush the gasket. With a lot more pressure than they typical two stroke with springs. If properly installed the seam doesn't even see exhaust pressure as it is on the outer surface past the centerline where the sealing takes place.
Header paint or other high heat coating will provide some rust protection. No idea how long it will last. It's far enough from the head pipes that it could hold up and protect from road spray. There are professional ceramic coatings that I know work great, but not really a DIY project as they have to be baked on. No idea if the spray can ceramics are snake oil or if they really work.

̶ ̶P̶e̶s̶s̶i̶m̶i̶s̶t̶ C̶y̶n̶i̶c̶ Realist


Ya. I paid attention how the old gaskets came out. They were all different. So I'd say it doesn't matter. But just for fun I put them all with the seam on the outside.
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Re: 1500 header install. Gasket tack?

Post by Quick Cal »

Greenwinger wrote: Sun May 14, 2023 9:37 am Due to ongoing leaking issues with my header to collector box I had to change them 4 times in one month trying to fix the small exhaust leak. I've got it down to changing the header gaskets to about 15 min. Just be careful installing them I have never had much trouble with them. and as Rambozo states make sure to get the old ones out. Don't over tighten the bolts either, If I'm not mistaken the spec. is 7 lb/ft ( I am probably wrong )which I always found a little light. You will feel the washers crush as you tighten them. Remember to go over all the bolts several times until they are all the same snugness. And if possible use the OEM copper gaskets the aftermarket ones don't last long and don't seem to seal very well, well not for me anyways. Good luck
I used all oem gaskets and replaced them all. Headers and muffler joints.

I've got small leaks on all 4 chamber connections. On my new/used chamber I can see a groove in it from the clamp. I wonder if it's leaking there? Might be able to see it in a previous pic above. My clamps were all distorted and so was the mufflers. I was hoping they would all true them self's up?

So how did you fix your leaks?
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Re: 1500 header install. Gasket tack?

Post by Charlie1Horse »

Those gaskets are pretty lightweight so I just put two touches of wheel bearing grease one on each side across the gasket and it keeps them in place until I get the header in place. It burns right off as soon as you start it up.
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Re: 1500 header install. Gasket tack?

Post by Greenwinger »

Quick Cal wrote: Mon May 15, 2023 8:12 pm I've got small leaks on all 4 chamber connections. On my new/used chamber I can see a groove in it from the clamp. I wonder if it's leaking there? Might be able to see it in a previous pic above. My clamps were all distorted and so was the mufflers. I was hoping they would all true them self's up?

So how did you fix your leaks?
My final attempt was to install new clamps and mesh gaskets and then coat the whole thing with muffler cement. It seem to work for a little while and then the leaks returned. So now I just turn up my radio and drive on. They are such small leaks they should plug up from exhaust gases on their own if I would just leave them alone for a while. :D


Years ago I also removed the collector box cleaned it up and sprayed on 3 coats of high heat header paint, she seems to be holding up quite well. Except for the small leaks of course :lol:
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Re: 1500 header install. Gasket tack?

Post by FM-USA »

If you have round copper exhaust O-Rings with the flat side on one side, that flat DOES go towards the engine. If that washer is OEM 100% round, it does not matter which direction it goes.

So why does a copper O-Ring seal burn out?
That flat side is designed to transfer heat to the engine's cooling fins or water jacket.
If a part of the round o-ring isn't equally or fully crushed all the way around, it has less area to transfer said heat & that small area can overheat & burn.

My Triumph 500 twin had a header flange with fins. Offhand I don't remember 50+ years ago how it sealed but I do remember wrapping a few turns of my dad's asbestos rope as the exhaust seal. Worked just fine, might have been better than OEM of that day.

.


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