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Old 11-06-2011, 08:27 AM
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I tried every gasket I could find on my block huggers. The only thing that holds up is copper. I took a 1/2 in thick piece of cold rolled steel and contact cemented sandpaper on it to start the header flattening exercise. At first I just scratched the high spots and used a large flat file to dress them. Gradually more and more of the surfaces became square. I also took the die grinder as you did and narrowed the "o-ring" on the ports of the headers. This pretty well cured the problem. You have to retighten the bolts a few times to set the gasket but once done they seem to stay tight. I replace the gaskets in the winter each year. You can anneal them but why mess with them as much trouble as they can be???
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