Exhaust Flange Gaskets Alternative

[Patrini]

Hi,

I have a AE92 4AGZE that I use in a Clubman mostly on the race track.

I have a problem with the 2 flange gaskets that seal between the cast iron manifold and the down pipe.

They seal fine on the road but with the high temps I get on the track they are only really good for 1 track session before they start blowing. The 3 studs are in gd condition and I use the toyota std nuts and gaskets. Nuts stay tight and flange stays tight but gaskets still do not last.

So has anybody found an alternative flange gasket that survives at high temperature, or can recomend alternative material that I can make some from which will survive ????

I am thinking perhaps solid copper anealed may do the trick ??

Thks,

Chrs, pat

[CELICASUPRA7M]

multi layered stainless is your friend

[oldcorollas]

does the downpipe have a little sleeve in it that goes up into the cast part?
that could assist by not letting the exhaust directly attack the gasket..

[oldeskewltoy]

could you swap it for a different factory manifold... say from a 20V?

[Patrini]

Hi Guys,

Thks for the replies.

Not sure if multilayer stainless sheet is readily available, not managed to google any up, seems to be normally bought as complete gaskets - Cometic head etc.

Old Corrola's - Funny you should mention the small sleeve that runs up into the manifold section, just had the exhaust appart again and noticed that this time only 1 gasket is totally cactus. It is the one that has a much smaller sleeve section. Was thinking I might extend the sleeve for a bit of heat protection, thks for confirming my thoughts.

Still would like to at least make a secondary gasket to go around the normal round flange gaskets, or prefrebaly replace them with something else.

Thought the 20V manifold required a bit of modifcation to fit. Also wonder if it would bolt up to my downpipe. Does the 20V use different better/flange arrangement ??

Chrs, Pat

[JP]

are you using genuine exhaust gaskets? Maybe get the header flange machined if it's blowing out genuine gaskets, a slightly warped flange will blow out most gaskets.

[Patrini]

Yes have used both genuine and ACL, I think the problem is the reduced size of the small sleeve that runs up into the manifold section - as stated above. I have now made up a sleeve to make each sleeve the correct length. Will try that on the track this w/end and see how it holds.

I did check the flanges for warping previously and both manifold and downpipe okay.

Chrs, PAt

[3sgte]

Do you have any photos?
I have never seen issues with properly sized Toyota gaskets.
Is the dealer supplying the proper OEM type spiral pink/light blue/green gaskets?

Insufficient crush=certain failure
Oversized gasket (sits outside the gasket groove preventing proper flange clamping)=certain failure