<div dir="ltr">Well drove the car last night and today, NO more exhaust leaks . I can't say if it was fixing the header flare and getting the metal ring to seat better or if the permatex sealer helped .<div><br></div><div>William</div></div><div class="gmail_extra"><br><div class="gmail_quote">On Sun, Aug 5, 2018 at 3:58 PM, William Jahn <span dir="ltr"><<a href="mailto:willjahn975@gmail.com" target="_blank">willjahn975@gmail.com</a>></span> wrote:<br><blockquote class="gmail_quote" style="margin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex"><div dir="ltr">I used a small screw driver to get the metal ring up against the mesh crush ring/seal because it was only hitting at best half the crush ring . I got it to contact all the way around so it's even now. I even took a 1/4" square metal bar stock I had to try the beat the empi header so called cone lip so it was more of a inside cone shape the filed the outer edge to a bevel so the clamp would not stop against it. Did this before filing or adding sealer . I think the main issue was both the sealing surface of the header and the metal ring not seating fully around the mesh crush ring which is all this sort of clamp/seal system does . The crush ring does fit snug on the HE pipe. <span class="HOEnZb"><font color="#888888"><div><br></div><div>William</div></font></span></div><div class="HOEnZb"><div class="h5"><div class="gmail_extra"><br><div class="gmail_quote">On Sun, Aug 5, 2018 at 3:48 PM, William Jahn <span dir="ltr"><<a href="mailto:willjahn975@gmail.com" target="_blank">willjahn975@gmail.com</a>></span> wrote:<br><blockquote class="gmail_quote" style="margin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex"><div dir="ltr">Yesterday I took a look at the empi header to the right HE pipe . I removed the clamp and was able to check the HE OD and it was 35 mm . I could only pull the header back 3/16'" . I was not in the frame of mind with the excessive heat we have here to remove the header . What I did was pull the header back the 3/16" insert a block of wood to hold it there and tried to insert the .011" aluminum sheet I have . Since the header end was sort of oval shaped I really could not get even one wrap of aluminum sheet in there. What I ended up doing was using the permatex ultra copper gasket maker and getting it in the header gap and rotated the crush seal to spread it around the header and filed the header flange so the clamp would fit better. Then once I felt the Permatex was in there enough and put the clamp back in place and found the metal ring was not seating well and backed off the clamp and forced the ring to fit well then tightened the clamp. I let it sit now over 24 hours and have not started the car yet. My hope is it will seal the leak and if not I'll remove the header . I just didn't want to mess up the seal on the left since it does not leak. The empi header flange on the right was not formed right as far as I can tell . It's the header not the HE pipe . Now that the permatex is at least sealing the crush ring to the header flange and the metal ring now sits against the crush seal hopefully this will fix it at least until I can either replace the system with something better or see what I can do with the empi cheapo header removed . If the sealer blows out which I sort of doubt it will then I'll see what I can do. I just can't handle the noise the leak makes . <div><br></div><div>William </div></div><div id="m_719613739458156596m_-1708641935307720709DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2"><br>
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</tbody></table><a href="#m_719613739458156596_m_-1708641935307720709_DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2" width="1" height="1"></a></div><div class="m_719613739458156596HOEnZb"><div class="m_719613739458156596h5"><div class="gmail_extra"><br><div class="gmail_quote">On Sat, Jul 28, 2018 at 10:35 AM, Jim Adney <span dir="ltr"><<a href="mailto:jadney@vwtype3.org" target="_blank">jadney@vwtype3.org</a>></span> wrote:<br><blockquote class="gmail_quote" style="margin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex"><span>On 27 Jul 2018 at 17:27, William Jahn wrote:<br>
<br>
> Does anyone know what a good HE pipe OD is. <br>
<br>
</span>I don't have anything here that's completely rust free, but from various things <br>
I can measure, it looks like it must be ~34 mm.<br>
<span><br>
> Also thought I had two old crush seals on the j pipes they are the mesh<br>
> crap. <br>
<br>
</span>I was also disapppointed when I saw that the old style seals had been <br>
discontinued. I assume that was because they must have had asbestos in <br>
them, so getting rid of them was necessary.<br>
<br>
OTOH, I've had good luck with the metal mesh ones, and looking back at it, I <br>
suspect they could be smeared with muffler cement and work even better. <br>
That's what I'll do next time.<br>
<span class="m_719613739458156596m_-1708641935307720709HOEnZb"><font color="#888888"><br>
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-- <br>
******************************<wbr>*<br>
Jim Adney, <a href="mailto:jadney@vwtype3.org" target="_blank">jadney@vwtype3.org</a><br>
Madison, Wisconsin, USA<br>
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